Download Safety Manual

Safety Manual
DS230 / DS240 series
Safety monitor for SinCos and incremental encoders / sensors
Product features:
•
•
•
•
•
•
•
Monitoring underspeed, overspeed, standstill and direction of rotation
SIL3 and PLe certification
Safety functions equivalent to EN61800-5-2 (SS1, SS2, SOS, SLS, SDI, SSM)
Mounting to 35 mm top hat rail (according to EN 60715)
USB interface for simple parametrization by the OS 6.0 operator surface
Optional available display and programming unit BG230 for parametrization and indication
Inputs for:
2 SinCos encoders
2 RS422 incremental encoders
2 HTL/PNP incremental encoders, proximity switches or control signals
• Outputs:
1 Relay Output 5 … 36 VDC (NO), (safety related)
1 Analog Output 4 … 20 mA, (safety related)
4 Control HTL Outputs, (safety related)
• Signal splitter:
1 SinCos Splitter Output, (safety related)
1 RS422 Splitter Output, (safety related)
Available devices:
 DS230: All inputs and outputs as well as signal splitter function
 DS236: All inputs and outputs, but without signal splitter function
 DS240: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, with signal splitter function
 DS246: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, without signal splitter
motrona GmbH, Zwischen den Wegen 32, DE - 78239 Rielasingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, [email protected], www.motrona.com
Version:
Ds23001a_oi_e.doc/mb/07/14
Ds23003a_oi_e.doc/sn/ag/06/15
Description:
First edition pre series
First edition series
Rechtliche Hinweise:
All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH. Any
reproduction, modification, usage or publication in other electronic and printed media as well as in the
internet requires prior written authorization by motrona GmbH.
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Table of Contents
1. Safety Instructions and Responsibility ......................................................... 5
1.1.
1.2.
1.3.
1.4.
General Safety Instructions .................................................................................. 5
Use according to the intended purpose ................................................................ 5
Installation ............................................................................................................ 6
Cleaning, Maintenance and Service Notes .......................................................... 6
2. Introduction ................................................................................................. 7
3. Available Models ........................................................................................ 8
4. Block Diagrams and Connections ................................................................. 9
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
4.8.
DS230 Block Diagram ........................................................................................... 9
DS230 Connections ............................................................................................... 9
DS236 Block Diagram ......................................................................................... 10
DS236 Connections ............................................................................................. 10
DS240 Block Diagram ......................................................................................... 11
DS240 Connections ............................................................................................. 11
DS246 Block Diagram ......................................................................................... 12
DS246 Connections ............................................................................................. 12
5. Description of Connections .........................................................................13
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
5.8.
5.9.
5.10.
5.11.
5.12.
5.13.
5.14.
Power Supply ...................................................................................................... 14
Encoder Supply ................................................................................................... 15
SinCos-Inputs ...................................................................................................... 19
RS422-Inputs ....................................................................................................... 20
HTL / Control Inputs ............................................................................................ 21
SinCos-Splitter-Output ........................................................................................ 22
RS422-Splitter-Output......................................................................................... 23
Analog-Output 4 to 20 mA .................................................................................. 24
Control-Outputs ................................................................................................... 25
Relay-Output ....................................................................................................... 26
DIL switch ........................................................................................................... 27
Interface for Display Unit BG230 ........................................................................ 28
USB Interface for the OS6.0 Operator Surface ................................................... 29
LEDs / Status Indication...................................................................................... 30
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6. Operational Modes .....................................................................................31
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
6.8.
6.9.
6.10.
6.11.
6.12.
6.13.
6.14.
6.15.
Operational Modes of DS23x types .................................................................... 31
Operational Mode of DS24x types...................................................................... 32
Achievable Safety Levels of DS23x .................................................................... 33
Achievable Safety Level of DS24x ...................................................................... 34
„Operational Mode“ = 0 (DS23x) ........................................................................ 35
„Operational Mode“ = 0 (DS24x) ........................................................................ 36
„Operational Mode“ = 1...................................................................................... 37
„Operational Mode“ = 2...................................................................................... 38
„Operational Mode“ = 3...................................................................................... 39
„Operational Mode“ = 4...................................................................................... 40
„Operational Mode“ = 5...................................................................................... 41
„Operational Mode“ = 6...................................................................................... 42
„Operational Mode“ = 7...................................................................................... 43
„Operational Mode“ = 8...................................................................................... 44
„Operational Mode“ = 9...................................................................................... 45
7. Start-Up the Unit ........................................................................................46
7.1.
7.2.
7.3.
7.4.
Setup by PC ......................................................................................................... 47
Setup by the Programming Module BG230 ........................................................ 48
Parameter / Menu Overview............................................................................... 49
Parameter Description ........................................................................................ 51
8. Start-Up the Plant .......................................................................................78
8.1.
8.2.
8.3.
8.4.
8.5.
8.6.
8.7.
Cabinet installation ............................................................................................. 78
Parametrization ................................................................................................... 79
Preparation before first start-up ......................................................................... 84
Checklist for Parameter Settings ........................................................................ 85
Definition of the Directions................................................................................. 85
Sensor Channel Adaption ................................................................................... 86
Completion of Commissioning ............................................................................ 88
9. Error Detection ...........................................................................................89
9.1.
9.2.
9.3.
9.4.
9.5.
Error Representation ........................................................................................... 89
Initial Error .......................................................................................................... 90
Runtime Error ...................................................................................................... 91
Error Clearing ...................................................................................................... 93
Error Detection Time ........................................................................................... 93
10. Parameter List ............................................................................................94
11. Technical Specifications .............................................................................97
11.1. Dimensions ......................................................................................................... 99
12. Certificate ................................................................................................ 100
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1. Safety Instructions and Responsibility
1.1. General Safety Instructions
This operation manual is a significant component of the unit and includes important rules and hints
about the installation, function and usage. Non-observance can result in damage and/or impairment
of the functions to the unit or the machine or even in injury to persons using the equipment!
Please read the following instructions carefully before operating the device and observe all safety
and warning instructions! Keep the manual for later use.
A pertinent qualification of the respective staff is a fundamental requirement in order to use these
manual. The unit must be installed, connected and put into operation by a qualified electrician.
Liability exclusion: The manufacturer is not liable for personal injury and/or damage to property and
for consequential damage, due to incorrect handling, installation and operation. Further claims, due
to errors in the operation manual as well as misinterpretations are excluded from liability.
In addition the manufacturer reserves the right to modify the hardware, software or operation
manual at any time and without prior notice. Therefore, there might be minor differences between
the unit and the descriptions in operation manual.
The raiser respectively positioner is exclusively responsible for the safety of the system and
equipment where the unit will be integrated.
During installation or maintenance all general and also all country- and application-specific safety
rules and standards must be observed.
If the device is used in processes, where a failure or faulty operation could damage the system or
injure persons, appropriate precautions to avoid such consequences must be taken.
1.2. Use according to the intended purpose
The unit is intended exclusively for use in industrial machines, constructions and systems. Nonconforming usage does not correspond to the provisions and lies within the sole responsibility of the
user. The manufacturer is not liable for damages which are arisen through unsuitable and improper
use. Please note that device may only be installed in proper form and used in a technically perfect
condition in accordance to the technical specifications (see chapter 11). The device is not suitable
for operation in explosion-proof areas or areas which are excluded by the EN 61010-1 standard.
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1.3. Installation
The device is only allowed to be installed and operated within the permissible temperature range.
Please ensure adequate ventilation and avoid all direct contact between the device and hot or
aggressive gases and liquids.
Before installation or maintenance, the unit must be disconnected from all voltage-sources. Further
it must be ensured that no danger can arise by touching the disconnected voltage-sources.
Devices which are supplied by AC-voltages, must be connected exclusively by switches, respectively
circuit-breakers with the low voltage network. The switch or circuit-breaker must be placed as near
as possible to the device and further indicated as separator.
Incoming as well as outgoing wires and wires for extra low voltages (ELV) must be separated from
dangerous electrical cables (SELV circuits) by using double resp. increased isolation.
All selected wires and isolations must be conforming to the provided voltage- and temperatureranges. Further all country- and application-specific standards, which are relevant for structure, form
and quality of the wires, must be ensured. Indications about the permissible wire cross-sections for
wiring are described in the technical specifications (see chapter 11).
Before first start-up it must be ensured that all connections and wires are firmly seated and secured
in the screw terminals. All (inclusively unused) terminals must be fastened by turning the relevant
screws clockwise up to the stop.
Overvoltage at the connections must be limited to values in accordance to the overvoltage category
II.
For placement, wiring, environmental conditions as well as shielding and earthing/grounding of the
supply lines the general standards of industrial automation industry and the specific shielding
instructions of the manufacturer are valid. Please find all respective hints and rules on
www.motrona.com/download.html --> [General EMC Rules for Wiring, Screening and Earthing].
1.4. Cleaning, Maintenance and Service Notes
To clean the front of the unit please use only a slightly damp (not wet!), soft cloth. For the rear no
cleaning is necessary. For an unscheduled, individual cleaning of the rear the maintenance staff or
assembler is self-responsible.
During normal operation no maintenance is necessary. In case of unexpected problems, failures or
malfunctions the device must be shipped for back to the manufacturer for checking, adjustment or
reparation. Unauthorized opening and repairing can have negative effects or failures to the
protection-measures of the unit.
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2. Introduction
This series of speed monitors is suitable for safety-related monitor tasks e. g. over-speed, underspeed, standstill and direction of rotation. This SIL3/PLe certified generation of devices was
developed to achieve functional safety by supporting a wide range of sensors and encoders in
different combinations.
Due to its innovative multifunctional inputs these devices are perfectly suitable for the retrofitting of
existing plants and machines which are using “non-safe“ sensors. This offers a great opportunity to
save costs for expensive and certified sensors. Also the costs for new installations and adjustments
can be reduced significantly by using the existing components and wiring.
Typical examples are centrifuges, cranes, wind power or hauling plants.
Special features:
 Additionally suitable for a "Set-Up Operation",
e. g. for manual settings at plants with open doors and reduced speed
 All models are safety-related and dually certified according to
EN 61508, EN 62061 / SIL3 and EN ISO 13849-1 Cat. 3 / Ple,
even when using “non-safety-related” standard sensors or encoders
 Wide input frequency range and fast response time
 Very versatile range of possible monitoring functions
 Easy setup by PC via USB or by the optional programming module BG230
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3. Available Models
D S 2 x x
Unit
D=
Speed Monitor
Application
S=
Safety Applications
Housing
Housing for DIN rail mounting into a control
2=
cabinet (according to EN 60715)
Inputs
3=
4=
2 Inputs for SinCos encoders
2 Inputs for incremental RS422 encoders
2 Inputs for HTL/PNP incremental encoders
or HTL/PNP control signals
1 Input for SinCos encoder with SIL3 / PLe
2 Inputs for HTL/PNP control signals
Outputs
1
1
0= 4
1
1
1
6= 1
4
Relay Output
Analog Output
Control Outputs
SinCos Splitter Output
RS422 Splitter Output
Relay Output
Analog Output
HTL Control Outputs
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4. Block Diagrams and Connections
4.1. DS230 Block Diagram
4.2. DS230 Connections
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4.3. DS236 Block Diagram
4.4. DS236 Connections
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4.5. DS240 Block Diagram
4.6. DS240 Connections
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4.7. DS246 Block Diagram
4.8. DS246 Connections
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5. Description of Connections
This chapter describes only the electrical connections and their general function. For a detailed
technical information please refer the chapter 11.
Name
X1 | RELAY OUT
Description see chapter
5.10 Relay-Output
X2 | CONTROL OUT
5.9 Control-Outputs
X3 | 24V IN
5.1 Power Supply
X4 | ANALOG OUT
5.8 Analog-Output 4 to 20 mA
X4 | RS 422 OUT
5.7 RS422-Splitter-Output
X5 | SINCOS OUT
5.6 SinCos-Splitter-Output
X6 | SINCOS IN 1
5.3 SinCos-Inputs
X7 | SINCOS IN 2
5.3 SinCos-Inputs
X8 | RS422 IN 1
5.4 RS422-Inputs
X9 | RS422 IN 2
5.4 RS422-Inputs
X10 | CONTROL IN
5.5 HTL / Control Inputs
X11
5.12 Interface for Display Unit BG230
X12
5.13 USB Interface for the OS6.0 Operator Surface
S1
5.11 DIL switch
ERROR - ON
5.14 LEDs / Status Indication
All outputs perform safe. The connection to the outputs is only safe if the sequential
device is able to detect the fault status of each output.
In order to prevent simultaneous damages to the cables by external influences,
the encoder resp. sensor lines must be kept physically separate from one another.
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5.1. Power Supply
If the unit is connected to a DC power supply network, which supplies further devices or systems, it
must be ensured that no voltages ≥ 60 V can occur at the terminals X3:1 and X3:2.
If this cannot be ensured, the unit must be supplied by a separate DC power pack, which may not be
connected to further devices or systems.
The requirements for both kinds of power supply are:
 Nominal voltage range from 18 … 30 VDC
 Ripple < 10% @ 24 V
 External fuse (2.5 A, medium time lag) required
A separate power pack must cover the following requirements:
 The switch-on current of the unit is maximum 2.5 A
 The consumption of the unit is maximum 45 W
The 18 … 30 VDC power supply must be connected by the pluggable 2-pin screw terminal [X3].
The power supply input is protected by an internal reverse polarity protection.
pluggable 2-pin screw terminal [X3]

The input must be protected by an external fuse
(type and value see chapter 11. “Technical Specifications”).

A SIL3 certified power supply can be used without any further external
components or protections.
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5.2. Encoder Supply
The unit offers an auxiliary voltage output to power the used encoder resp. sensors.
The power supply of the encoders must be carried out directly from the safety unit
(see chapter 5.2.1) or in use of an external power supply via a relay (see chapter 5.2.2).
Encoder supply: SinCos inputs [X6] [X7]
Encoder supply: RS422 inputs [X8] [X9]
HTL encoders or sensors must also be connected to the encoder supply of the RS422 inputs
The maximum load of encoder supply is 200 mA each channel (Sensor1 and Sensor2).
Supply
Sensor1
SinCos inputs
RS422 inputs
HTL inputs
[X6:4] [X6:5]
[X8:1] [X8:2]
[X8:1] [X8:2]
Sensor2
[X7:4] [X7:5]
[X9:1] [X9:2]
[X9:1] [X9:2]
Examples for the connection of encoders and the encoder supply can be found in chapter 6.
When powering up the encoder supply, the maximum input current of the safety unit can be
exceeded due to different encoders. In this case, the encoder supply will not be enabled and an error
appears (see chapter 9).
In case of such problems or if another voltage level is required, the encoder supply can be switched
via a relay by an external voltage source. The relay activation must essentially be performed by the
encoder supply of safety unit (see chapter 5.2.2).

In case of a direct encoder supply it is mandatory to operate the encoders with the
auxiliary voltage from the unit.

An external encoder supply must be done in each case via a relay which is triggered
by the auxiliary voltage of the unit.
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5.2.1. Direct Encoder Supply
The unit provides an auxiliary encoder supply for each sensor channel
(HTL encoders must be supplied by the encoder supply for the RS422 inputs).
The level of the supply voltage is approximate 2 V below the 18 … 30 VDC power supply
at terminal [X3].
The maximum load of encoder supply is 200 mA each channel (Sensor1 and Sensor2).
Supply
Sensor1
SinCos inputs
RS422 inputs
HTL inputs
[X6:4] [X6:5]
[X8:1] [X8:2]
[X8:1] [X8:2]
Sensor2
[X7:4] [X7:5]
[X9:1] [X9:2]
[X9:1] [X9:2]
Example of a direct encoder supply

In case of a direct encoder supply it is mandatory to supply the encoders with the
auxiliary voltage from the unit.
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5.2.2. External Encoder Supply
An external encoder supply must be done in each case via a relay which is triggered by the auxiliary
voltage of the unit. This is necessary, because the encoder supply will only be activated after the
safety unit has successfully completed its initialization and self-test.
In case of a relay failure or a failure of the external encoder voltage (switched by the relay), the
operator must ensure that the plant cannot reach a safety-critical state.
Explanation / Solution:
In case of an encoder supply failure the encoder would "rotate", but the unit is incapable to detect
speed or speed differences. In order to detect this error, the operator can use e. g. a control output
of the unit which indicates "standstill" (see Section 7.4.6). A master controller has to compare these
two states (plant "rotate" and control output "standstill"). If the two states differ the master
controller has to trigger an error and the plant has to go to a safe state.
Example of an external encoder supply (1 encoder is switched via 1 relay)


An external encoder supply must be done in each case via a relay which is triggered by
the auxiliary voltage of the unit.
The operator must ensure that the plant cannot reach a safety-critical state, in case of
a failure of the relay or a failure of the external encoder voltage (switched by the relay).
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Continuation “External Encoder Supply”
Example of an external encoder supply (2 encoders are switched via 1 relay)


An external encoder supply must be done in each case via a relay which is triggered by
the auxiliary voltage of the unit.
The operator must ensure that the plant cannot reach a safety-critical state, in case of a
failure of the relay or a failure of the external encoder voltage (switched by the relay).
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5.3. SinCos-Inputs
If the operational mode is set for using SinCos encoders (see chapter 7.4.1 / Parameter 000), the unit
will accept SinCos input signals with 1 Vpp and 2.5 V DC-offset at the 9-pin SUB-D connectors [X6]
and [X7].
It is mandatory to connect up always all existing signal lines (SIN+, SIN-, COS+ and COS-). The
internal SinCos encoder signal monitor verifies the Common Mode range of each signal line and is
capable to detect cable fractures.
An evaluation option for any existing reference signals (REF+ and REF-) is not applicable.
All input lines are already terminated by internal 120 Ohm load resistors.
The SinCos encoder must use the corresponding encoder supply at pin 4 and pin 5 of the connector
(see chapter 5.2).
male SUB-D connector [X6], [X7]
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5.4. RS422-Inputs
(Only DS230 and DS236)
If the operational mode (see chapter 7.4.1 / Parameter 000) is set for RS422 encoder use, the unit
will accept differential input signals from an incremental encoder in RS422 format at the terminal
strips [X8] and [X9]. The RS422 input channels (A and /A resp. B and /B) are internally terminated by
a dynamic terminating circuit (220 pF / 120 ohm).
It is mandatory to connect up all signal lines (A, /A, B and /B).
An evaluation option for any existing zero pulses (or Z / Z) does not exist.
The RS422 encoder must use the encoder supply at pin 1 and 2 of the respective terminal
(see chapter 5.2).
pluggable 7-pin screw terminal [X8], [X9]
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5.5. HTL / Control Inputs
The screw terminal [X10 | CONTROL IN] has two inputs for signals with HTL level and PNP switching
characteristic. Each of the inputs performs complementary.
Depending on the operational mode (see chapter 7.4.1 / Parameter 000), the control inputs [X10 |
CONTROL IN] can be configured as frequency or as command inputs:
Frequency input for HTL encoders (A / B / 90°):
Sensor1
[X10 | CONTROL IN]
incremental HTL encoder
Sensor2
[X10 | CONTROL IN]
incremental HTL encoder
[X10:2]
[X10:3]
[X10:4]
[X10:5]
channel A
channel B
channel A
channel B
HTL encoders must be supplied by the encoder supply of the RS422 inputs (chapter 5.2.).
Frequency input for HTL encoders (A) or a proximity switch:
Sensor1
[X10 | CONTROL IN]
incremental HTL encoder
Sensor2
[X10 | CONTROL IN]
incremental HTL encoder
[X10:2]
[X10:3]
[X10:4]
[X10:5]
channel A
unconnected / direction signal
channel A
unconnected / direction signal
e. g. to evaluate a gear wheel by connecting a proximity switch.
The inputs [X10:3] resp. [X10:5] may be unconnected (internal pull-down) or can be used for a static
direction signal. HTL encoders must be supplied by the encoder supply of the RS422 inputs (see 5.2).
Control input for HTL commands:
Control1
[X10 | CONTROL IN]
Control2
[X10 | CONTROL IN]
[X10:2]
[X10:3]
[X10:4]
HTL/PNP control signal
[X10:5]
HTL/PNP control signal
direct control signal
complementary control signal
direct control signal
complementary control signal
Basically always the complementary signal of the direct input must be applied to the inverted input.
Any other conditions are invalid and are detected as an error by the unit.
For more information about the control inputs see chapter 7.4.7.
pluggable 5-pin screw terminal [X10]


It does not make sense to configure the unit for a connection of 2 HTL encoders
simultaneously, because then no more inputs for external commands are available.
With DS24x units, the HTL/PNP inputs can only be used as control-inputs for external
commands.
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5.6. SinCos-Splitter-Output
(only DS230 and DS240)
The DS230 respective the DS240 has a safety-related SinCos-Splitter-Output. Depending on the
selected operating mode (0, 1, 2 or 6), the integrated splitter function allows to reproduce the signal
at input terminal [X6 | SINCOS IN 1] to the female 9-pin SUB-D connector [X5 | SINCOS OUT]. Thus the
encoder signal connected to [X6 | SINCOS IN 1] can be processed by a further target device.
The signal delay time between SinCos input and SinCos output is approximately 200 ns.
The channels SIN+ and SIN- resp. COS+ and COS- must be terminated by 120 Ohm load resistors at
the target device.
In case of errors, the DC-offset of the SinCos output is shifted in order to signalize the error
condition to the target device.
The connection to the SinCos splitter output is only safe, if the following device includes a SinCos
monitoring system and can detect the offset error.
female SUB-D Connector [X5]
 The channels SIN+ and SIN- resp. COS+ and COS- must be terminated by
120 Ohm load resistors at the target device.
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5.7. RS422-Splitter-Output
(only DS230 and DS240)
The DS230 respective the DS240 has a safety-related RS422-Splitter-Output. Depending on the
selected operating mode, the integrated splitter function allows to reproduce an input frequency to
the output terminal X4 | RS422 OUT. Thereby the RS422 signal can be processed by a further device.
The block diagrams (see chapter 4) give an overview.
The device evaluates two frequency channels. Which input is assigned to which channel is set in the
operating mode (see chapter 7.4.1 / Parameter 000). The splitter output allows to reproduce the
input frequency from one of these channels (see chapter 7.4.9).
Independent from the input signal (SinCos resp. HTL), always incremental RS422 square-wave
pulses are generated at [X4 | RS422 OUT].
The signal delay time between the RS422 input and the RS422 output is approximately 600 ns.
In case of an error, no more incremental signals are available at the RS422 output (Tri-State with
pull-down cut off).
The connection to the RS422 Splitter output is only safe if the following device is capable to detect
the error state of the safety unit.
pluggable 7-pin screw terminal [X4]
In DS230 / DS240 versions, the screw terminal [X4] is provided with 7 connections:
[X4 | ANALOG OUT] analog output
[X4:1-3]
[X4 | RS422 OUT]
RS422 output
[X4:4-7]
In DS236 / DS246 versions, the screw terminal [X4] has only 3 connections:
[X4 | ANALOG OUT] analog output
[X4:1-3]
[X4 | RS422 OUT]
not available!
With DS240 variants only the encoder frequency connected at input terminal
[X6 | SINCOS IN 1] can be exported to the RS422 splitter output.
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5.8. Analog-Output 4 to 20 mA
One safety-related analog output is available at the screw terminal [X4]. The current output is freely
scalable (see chapter 7.4.10). It delivers an output signal, which is proportional to one of the input
frequency (see chapter 7.4.1 / Parameter 003) and independent from the connected sensor types. In
case of an unused analog output [X4:2] and [X4:3] must be linked. An open analog output (e.g. wire
fracture) will release an error status.
During normal operation, the output moves in a proportional range from 4 to 20 mA.
In case of errors, the analog output is 0 mA.
The connection to the Analog-Output is only safe if the following device is capable to detect the
error state of the safety unit. In case of errors the operator is responsible to ensure safety conditions
to all system-parts and -components which are influenced by the analog output.
In DS230 / DS240 versions, the screw terminal [X4] is provided with 7 connections:
[X4 | ANALOG OUT] analog output
[X4:1-3]
[X4 | RS422 OUT]
RS422 output
[X4:4-7]
pluggable 7-pin screw terminal [X4] at DS230/DS240
In DS236 / DS246 versions, the screw terminal [X4] has only 3 connections:
[X4 | ANALOG OUT] analog output
[X4:1-3]
[X4 | RS422 OUT]
not available!
pluggable 3-pin screw terminal [X4] at DS236/DS246
 In case of an unused analog output [X4:2] and [X4:3] must be linked.
 An open analog output (e.g. wire fracture) will release an error status.
Ds230_03a_oi_e.doc / Jun-15
Page 24 / 100
5.9. Control-Outputs
Four safety-related HTL control outputs are available at the screw terminal [X2 | CONTROL OUT].
Each of the output performs complementary (OUT1, /OUT1 to OUT4, /OUT4).
The switching points and conditions are adjustable by Parameters (see chapter 7.4.5 and 7.4.6)
In normal state (no error, no switching conditions active) the non-inverted outputs offers LOW level
and the inverted outputs offers HIGH level. During HIGH state, the output level is about 2 V below
the supply voltage connected to terminal [X3 | 24V IN]. Each output has a push-pull output stage and
short circuit protection. When switching inductive loads, additional external suppression measures
are recommended.
In case of errors all outputs are LOW (no more inversion between Out_ and /Out_).
The connection to the Analog-Output is only safe if the following device is capable to detect the
error state of the safety unit.
pluggable 8-pin screw terminal [X2]
Example: Control-Output with inductive load (Relay)
OUT4 and /OUT4 safety-related wired
Example: Control-Outputs to PLC
OUT4 und /OUT4 safety-related wired
OUT3 not safety-related wired
Ds230_03a_oi_e.doc / Jun-15
Page 25 / 100
5.10. Relay-Output
The safety-related relay-output consists of two independent relays with force guided contacts. The
normally open contacts of the two relays (NO) are internally connected in series. At the 2-pin screw
terminal [X1 | RELAY OUT] the series-relay-contact can be tapped for integration into a safety circuit.
The contacts are only closed during normal and disturbance-free operation. They will open to its
safety state in case of errors or when the programmed switching condition (see chapter 7.4.5) is
fulfilled. In a de-energized state of the unit, the contacts are also open.
The switching points and conditions of the relay-output are freely programmable by parameters (see
chapter 7.4.5 and 7.4.6). Further the “opener” is also integrated within all monitoring functions.
In case of an error, the contact changes to its open and safe condition.
pluggable 2-pin screw terminal [X1]
internal connection [X1]
 In case of an open relay-contact, the operator is responsible to ensure
a safe state to all relevant parts and components of the equipment.
 The target unit must be able to evaluate edges, in order to determine dynamical
conditions of the relay output too.
 At frequencies close to the switching point, relay bouncing may occur through
the variance of the frequency measurement. To prevent this effect, a hysteresis
should be set (see parameter 053).
 If short oversteps of the switching point should be detected, a lock output should
be set (see parameter 057)
Ds230_03a_oi_e.doc / Jun-15
Page 26 / 100
5.11. DIL switch
The 3-position DIL switch [S1] is located at the front of the unit
(only accessible, if no display-unit is connected).
3-pos DIL switch [S1]
The following unit-states can be set by the DIL switch:
Slider
1
2
3
Condition
Unit-State
ON
„Normal Operation“ - Parameter access disabled
OFF
„Factory Settings“ - with next power-on, all Parameters will be reset to default values
ON
„Normal Operation“ - Parameter access disabled
OFF
„Self Test Message“ - with next power-on, the unit will transmit a self test protocol
via USB interface
(without “Self Test Message” booting of the start up is faster)
ON
„Normal Operation“ - Parameter access disabled
OFF
„Programming Mode“ – allows access to the Parameters (by display unit or PC)


„Programming Mode“ (DIL switch) only for start-up
Set all DIL switch sliders to „ON“ after start-up


Protect the DIL switch sliders after start-up (e. g. by covering with an adhesive tape)
Normal operation is only permitted when the yellow LED is permanently off

The safety function of the unit cannot be guaranteed before the commissioning
is completed.
5.11.1. Boot time
DIL Nr. 2
ON = Normal Operation
OFF = Self Test Message
Ds230_03a_oi_e.doc / Jun-15
Boot time
After connecting the supply voltage, the device is ready for operation
after about 2 s
After connecting the supply voltage, the device is ready for operation
after about 8 s
Page 27 / 100
5.12. Interface for Display Unit BG230
The serial interface serves for communication between the unit and an optional programming- and
display unit „BG320“, which can be plugged on the front.
8-pin female connector [X11]
The programming and display unit BG230 and the safety unit will be connected by plugging the
BG230 on the female 8-pin connector [X11] at the front.
Ds230_03a_oi_e.doc / Jun-15
Page 28 / 100
5.13. USB Interface for the OS6.0 Operator Surface
For communication between the unit and a PC or a super ordinate controller, a serial interface
simulation is accessible at the USB port. For connection a standard USB-cable with a „Type B“
connector is used. The USB cable is available as an option.
USB type B
The installation procedure of the USB driver file is described in the following document:
“Installation USB diver”
Ds230_03a_oi_e.doc / Jun-15
Page 29 / 100
5.14. LEDs / Status Indication
Two status LEDs are located at the front of the unit. The green one is marked as [ON] and the yellow
one as [ERROR].
Status LEDs
The green status LED uses the following two conditions:
LED (green)
Condition
OFF
Power off - no power supply voltage
ON
Power on - power supply voltage is ok
The yellow status LED uses the following four conditions:
LED (yellow)
OFF
ON
SLOW
FAST
Condition
Normal operation, self-test successfully completed, no error messages
After power on: the unit is running up, self-test in progress
During normal operation: error released by the process (divergence of frequencies etc.)
DIL1 = OFF: unit-state „Factory Settings“
DIL3 = OFF: unit-state „Programming Mode“
Error: incorrect self-test or internal error (see chapter 9. Error Detection)
OFF = LED if off, ON = LED is lighting
SLOW = slow flashing (approx. 1 Hz), FAST = fast flashing (approx. 2.5 Hz)

„Programming Mode“ (DIL switch) only for start-up

Set all (DIL switch) sliders to „ON“ after start-up


Protect the (DIL switch) sliders after start-up (e. g. by covering with an adhesive tape)
Normal operation is only permitted when the yellow LED is permanently off

The safety function of the unit cannot be guaranteed before the commissioning is
completed.
Ds230_03a_oi_e.doc / Jun-15
Page 30 / 100
6. Operational Modes
6.1. Operational Modes of DS23x types
The operational modes can be specified in the Main Menu (see chapter 8.4.1 / Parameter 000).
Mode
Sensor1
Sensor2
Control1
0
SinCos encoder at
[X6 | SINCOS IN 1]
SinCos encoder at
[X7 | SINCOS IN 2]
available for control available for control
signals
signals
1
SinCos encoder at
[X6 | SINCOS IN 1]
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
available for control
Not available!
signals
2
SinCos encoder at
[X6 | SINCOS IN 1]
HTL encoder (A) at
[X10 | CONTROL IN]
available for control
Not available!
signals
3
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
Not available!
Not available!
4
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
HTL encoder (A) at
[X10 | CONTROL IN]
Not available!
Not available!
5
HTL encoder (A) at
[X10 | CONTROL IN]
HTL encoder (A) at
[X10 | CONTROL IN]
Not available!
Not available!
6
SinCos encoder at
[X6 | SINCOS IN 1]
RS422 encoder at
[X9 | RS422 IN 2]
available for control available for control
signals
signals
7
RS422 encoder at
[X8 | RS422 IN 1]
RS422 encoder at
[X9 | RS422 IN 2]
available for control available for control
signals
signals
8
RS422 encoder at
[X8 | RS422 IN 1]
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
available for control
Not available!
signals
9
RS422 encoder at
[X8 | RS422 IN 1]
HTL encoder (A) at
[X10 | CONTROL IN]
available for control
Not available!
signals
Ds230_03a_oi_e.doc / Jun-15
Control2
Page 31 / 100
6.2. Operational Mode of DS24x types
In Case of DS24x, only “operational mode = 0” (see chapter 8.4.1 / Parameter 000) has to be used.
Mode
0
Sensor1
Sensor2
Control1
SIL3/PLe SinCos encoder
[X6 | SINCOS IN 1]
Sensor1 and Sensor2 are
internally bridged
available for control available for control
signals
signals
Ds230_03a_oi_e.doc / Jun-15
Control2
Page 32 / 100
6.3. Achievable Safety Levels of DS23x
To achieve a maximum of SIL3/PLe on system-level, no certificated sensors are required to fulfil the
integrity of the device. When using standard sensors, only the required safety level (by complying the
safety-related characteristics SFF, HFT, Type A/B, PFH, PFD resp. category, DCavg and MTTFd) and
systematic safety integrity must be ensured for the entire protection circuit. Software programs (like
SISTEMA) are very helpful for creating such evaluations of safety-related machine control systems
according to the EN ISO 13849 norm.
Mode Sensor1
Sensor2
0
SinCos encoder at
[X6 | SINCOS IN 1]
SinCos encoder at
[X7 | SINCOS IN 2]
1
SinCos encoder at
[X6 | SINCOS IN 1]
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
2
SinCos encoder at
[X6 | SINCOS IN 1]
HTL encoder (A) at
[X10 | CONTROL IN]
3
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
4
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
HTL encoder (A) at
[X10 | CONTROL IN]
5
HTL encoder (A) at
[X10 | CONTROL IN]
HTL encoder (A) at
[X10 | CONTROL IN]
6
SinCos encoder at
[X6 | SINCOS IN 1]
RS422 encoder at
[X9 | RS422 IN 2]
7
RS422 encoder at
[X8 | RS422 IN 1]
RS422 encoder at
[X9 | RS422 IN 2]
8
RS422 encoder at
[X8 | RS422 IN 1]
HTL encoder (A, B, 90°)
[X10 | CONTROL IN]
9
RS422 encoder at
[X8 | RS422 IN 1]
HTL encoder (A) at
[X10 | CONTROL IN]
Function
Achievable
Safety Level
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
Speed
Direction
Standstill
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****
SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****
**** A safety level can only be achieved in these cases, if it is physically ensured that there only
can be only one direction of rotary and linear movement. This can be realized for example by
using a self-locking gearbox.
Ds230_03a_oi_e.doc / Jun-15
Page 33 / 100
6.4. Achievable Safety Level of DS24x
To achieve a maximum of SIL3/PLe on system-level, a SIL3/PLe certificated sensor is required to fulfil
the integrity of the device. The required safety level (by complying the safety-related characteristics SFF,
HFT, Type A/B, PFH, PFD resp. category, DCavg and MTTFd) and systematic safety integrity must be
ensured for the entire protection circuit.
Software programs (like SISTEMA) are very helpful for creating such evaluations of safety-related
machine control systems according to the EN ISO 13849 norm.
Mode Sensor1
0
SIL3/PLe SinCos encoder
[X6 | SINCOS IN 1]
Ds230_03a_oi_e.doc / Jun-15
Sensor2
Function
Achievable
Safety Level
Sensor1 and Sensor2 are
internally bridged
Speed
Direction
Standstill
SIL3 / PLe
SIL3 / PLe
SIL3 / PLe
Page 34 / 100
6.5. „Operational Mode“ = 0 (DS23x)
Mode
Sensor1
Sensor2
Control1
Control2
0
[X6 | SINCOS IN 1]
[X7 | SINCOS IN 2]
[X10 | CONTROL IN]
[X10 | CONTROL IN]
Achievable
Safety Level
Speed
Direction
Standstill
SinCos encoder
SinCos encoder
HTL/PNP control signal
HTL/PNP control signal
(SIN+, SIN-, COS+, COS-)
(SIN+, SIN-, COS+, COS-)
(complementary)
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS23x) is used to evaluate a dual channel system, equipped with two SinCos
sensors resp. Encoders, which must be performed in accordance to chapter 5.3.




In this operational mode a DS230 variant reproduces always the input frequency at
[X6 | SINCOS IN 1] to the splitter output [X5 | SINCOS OUT].
A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].
The inputs at terminal [X8 | RS422 IN 1] and [X9 | RS422 IN 2] have no function.
At terminal [X10 | CONTROL IN] the inputs Control1 and Control2 are available
for control signals..
Ds230_03a_oi_e.doc / Jun-15
Page 35 / 100
6.6. „Operational Mode“ = 0 (DS24x)
Mode
Sensor1
Sensor2
Control1
Control2
0
[X6 | SINCOS IN 1]
SinCos encoder
Sensor1 and Sensor2 are internally bridged
[X10 | CONTROL IN]
HTL/PNP control signal
[X10 | CONTROL IN]
HTL/PNP control signal
Achievable
Safety Level
Speed
Direction
Standstill
(SIN+, SIN-, COS+, COS-)
(complementary)
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS24x) is exclusively used to connect a SIL3 resp. PLe certificated SinCos sensor
/encoder, which must be performed in accordance to chapter 5.3.


In this operational mode a DS240 variant reproduces always the input frequency at
[X6 | SINCOS IN 1] to the splitter outputs [X4 | RS422 OUT] and [X5 | RS422 OUT].
At terminal [X10 | CONTROL IN] the inputs Control1 and Control2 are available
for control signals.
Ds230_03a_oi_e.doc / Jun-15
Page 36 / 100
6.7. „Operational Mode“ = 1
Mode
Sensor1
Sensor2
Control1
Control2
1
[X6 | SINCOS IN 1]
SinCos encoder
[X10 | CONTROL IN]
Incremental HTL encoder
[X10 | CONTROL IN]
HTL/PNP control signal
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(SIN+, SIN-, COS+, COS-)
(A, B, 90°)
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two different
encoder types. Therefor a combination of a SinCos encoder and an incremental dual channel HTL
encoder is used. The SinCos encoder must be performed in accordance to chapter 5.3 and the
incremental encoder to chapter 5.5.
 In this operational mode a DS230 variant reproduces always the input frequency at
[X6 | SINCOS IN 1] to the splitter output [X5 | SINCOS OUT].
 A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].
 The inputs at [X7 | SINCOS IN 2], [X8 | RS422 IN 1] and [X9 | RS422 IN 2] have no
function.
 When connecting the HTL encoder to terminal [X10] pin 4, 5, the Control2
input is no more available. In this case only the Control1 input can be used.
Ds230_03a_oi_e.doc / Jun-15
Page 37 / 100
6.8. „Operational Mode“ = 2
Mode
Sensor1
Sensor2
Control1
Control2
2
[X6 | SINCOS IN 1]
SinCos encoder
[X10 | CONTROL IN]
Incremental HTL encoder
[X10 | CONTROL IN]
HTL/PNP control signal
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(SIN+, SIN-, COS+, COS-)
(A) single channel
(complementary)
 SIL3 / PLe
 SIL3 / PLe ****
 SIL3 / PLe ****
**** A safety level can only be achieved in these cases, if it is physically ensured that
there only can be only one direction of rotary and linear movement. This can be realized for
example by using a self-locking gearbox.
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two different
encoder types. Therefor a combination of a SinCos encoder and an incremental single channel HTL
encoder is used. The SinCos encoder must be performed in accordance to chapter 5.3 and the
incremental encoder to chapter 5.5.
 In this operational mode a DS230 variant reproduces always the input frequency at
[X6 | SINCOS IN 1] to the splitter output [X5 | SINCOS OUT].
 A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2 to the
splitter output [X4 | RS422 OUT].
 The inputs at [X7 | SINCOS IN 2], [X8 | RS422 IN 1] and [X9 | RS422 IN 2] have no function.
 When connecting the HTL encoder to terminal [X10] pin 4 and 5, the Control2 input is no
more available. In this case only the Control1 input can be used.
Ds230_03a_oi_e.doc / Jun-15
Page 38 / 100
6.9. „Operational Mode“ = 3
Mode
Sensor1
Sensor2
Control1
Control2
3
[X10 | CONTROL IN]
Incremental HTL encoder
[X10 | CONTROL IN]
Incremental HTL encoder
Control signal input not available
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(A, B, 90°)
(A, B, 90°)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two incremental
dual channel HTL encoders. The encoder must be performed in accordance to chapter 5.5.



A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].
The inputs at [X6 | SINCOS IN 1], [X7 | SINCOS IN 2], [X8 | RS422 IN 1] und [X9 |
RS422 IN 2] have no function.
Please note, that no more Control1 and Control2 inputs for external commands are
available, when connecting both encoders to terminal X10] pin 2, 3 and 4, 5.
Ds230_03a_oi_e.doc / Jun-15
Page 39 / 100
6.10. „Operational Mode“ = 4
Mode
Sensor1
Sensor2
Control1
Control2
4
[X10 | CONTROL IN]
Incremental HTL encoder
[X10 | CONTROL IN]
Incremental HTL encoder
Control signal input not available
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(A, B, 90°)
(A) single channel
 SIL3 / PLe
 SIL3 / PLe ****
 SIL3 / PLe ****
**** A safety level can only be achieved in these cases, if it is physically ensured that
there only can be only one direction of rotary and linear movement. This can be realized for
example by using a self-locking gearbox.
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two different
encoder types. Therefor a combination of an incremental dual channel HTL encoder as well as a
single channel HTL encoder is used. The connections of both encoders must be performed in
accordance to chapter 5.5.

A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].

The inputs at [X6 | SINCOS IN 1], [X7 | SINCOS IN 2], [X8 | RS422 IN 1] und [X9 |
RS422 IN 2] have no function.
Please note, that no more Control1 and Control2 inputs for external commands are
available, when connecting both encoders to terminal X10] pin 2, 3 and 4.

Ds230_03a_oi_e.doc / Jun-15
Page 40 / 100
6.11. „Operational Mode“ = 5
Mode
Sensor1
Sensor2
Control1
Control2
5
[X10 | CONTROL IN]
Incremental HTL encoder
[X10 | CONTROL IN]
Incremental HTL encoder
Control signal input not available
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(A) single channel
(A) single channel
 SIL3 / PLe
 SIL3 / PLe ****
 SIL3 / PLe ****
**** A safety level can only be achieved in these cases, if it is physically ensured that
there only can be only one direction of rotary and linear movement. This can be realized for
example by using a self-locking gearbox.
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two identical
encoder types. Therefor a combination of two incremental single channel HTL encoders is used. The
connections of both encoders must be performed in accordance to chapter 5.5.

A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].

The inputs at [X6 | SINCOS IN 1], [X7 | SINCOS IN 2], [X8 | RS422 IN 1] und [X9 |
RS422 IN 2] have no function.

Please note, that no more Control1 and Control2 inputs for external commands are
available, when connecting both encoders to terminal X10] pin 2 and 4.
Ds230_03a_oi_e.doc / Jun-15
Page 41 / 100
6.12. „Operational Mode“ = 6
Mode
Sensor1
Sensor2
Control1
Control2
6
[X6 | SINCOS IN 1]
[X9 | RS422 IN 2]
[X10 | CONTROL IN]
[X10 | CONTROL IN]
Achievable
Safety Level
Speed
Direction
Standstill
SinCos encoder
Incremental RS422 / TTL encoder
HTL/PNP control signal
HTL/PNP control signal
(SIN+, SIN-, COS+, COS-)
(A, /A, B, /B)
(complementary)
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two different
encoder types. Therefor a combination of a SinCos and a RS422/TTL encoder is used. The SinCos
encoder must be performed in accordance to chapter 5.3 and the RS422/TTL encoder to chapter 5.4.




In this operational mode a DS230 variant reproduces always the input frequency at
[X6 | SINCOS IN 1] to the splitter output [X5 | SINCOS OUT].
A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].
The inputs at [X7 | SINCOS IN 2] and [X8 | RS422 IN 1] have no function.
Both control inputs (Control1 and Control2) are available for control signals at [X10
| CONTROL IN].
Ds230_03a_oi_e.doc / Jun-15
Page 42 / 100
6.13. „Operational Mode“ = 7
Mode
Sensor1
Sensor2
Control1
Control2
7
[X8 | RS422 IN 1]
Incremental RS422 / TTL encoder
[X9 | RS422 IN 2]
Incremental RS422 / TTL encoder
[X10 | CONTROL IN] HTL/PNP control signal
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(A, /A, B, /B)
(A, /A, B, /B)
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS23x) allows to evaluate a dual channel system, equipped with two identical
RS422/TTL incremental encoders. The encoder must be performed in accordance to chapter 5.4.



A DS230 variant reproduces selectively the input frequency of Sensor1 or
Sensor2 to the splitter output [X4 | RS422 OUT].
The inputs at [X6 | SINCOS IN 1] and [X7 | SINCOS IN 2] have no function.
Both control inputs (Control1 and Control2) are available for control signals at
[X10 | CONTROL IN].
Ds230_03a_oi_e.doc / Jun-15
Page 43 / 100
6.14. „Operational Mode“ = 8
Mode
Sensor1
Sensor2
Control1
Control2
8
[X8 | RS422 IN 1]
Incremental RS422 / TTL encoder
[X9 | RS422 IN 2]
Incremental HTL encoder
[X10 | CONTROL IN] HTL/PNP control signal
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(A, /A, B, /B)
(A, B, 90°)
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
This mode (only DS23x) is used to evaluate a dual channel system, equipped by two different
incremental encoder resp. sensor types. Therefore an incremental RS422/TTL and a dual channel
HTL encoder are used. The RS422/TTL encoder must be performed in accordance to chapter 5.4 and
the HTL encoder to chapter 5.5.



A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].
The inputs at [X6 | SINCOS IN 1], [X7 | SINCOS IN 2] and [X9 | RS422 IN 2 have no
function.
When connecting the HTL encoder to terminal [X10] pin 4 and 5, the Control2 input
is no more available. In this case only the Control1 input can be used.
Ds230_03a_oi_e.doc / Jun-15
Page 44 / 100
6.15. „Operational Mode“ = 9
Mode
Sensor1
Sensor2
Control1
Control2
9
[X8 | RS422 IN 1]
Incremental RS422 / TTL encoder
[X9 | RS422 IN 2]
Incremental HTL encoder
[X10 | CONTROL IN] HTL/PNP control signal
Control signal input not available
Achievable
Safety Level
Speed
Direction
Standstill
(A, /A, B, /B)
(A) single channel
(complementary)
 SIL3 / PLe
 SIL3 / PLe
 SIL3 / PLe
**** A safety level can only be achieved in these cases, if it is physically ensured that there
only can be only one direction of rotary and linear movement. This can be realized for
example by using a self-locking gearbox.
This mode (only DS23x) is used to evaluate a dual channel system, equipped by two different
incremental encoder resp. sensor types. Therefore an incremental RS422/TTL encoder and a singlechannel HTL encoder are used. The RS422/TTL encoder must be performed in accordance to chapter
5.4 and the HTL encoder to chapter 5.5.

A DS230 variant reproduces selectively the input frequency of Sensor1 or Sensor2
to the splitter output [X4 | RS422 OUT].

The inputs at [X6 | SINCOS IN 1], [X7 | SINCOS IN 2] und [X9 | RS422 IN 2 have no
function.
When connecting the HTL encoder to terminal [X10] pin 4 and 5, the Control2 input
is no more available. In this case only the Control1 input can be used.

Ds230_03a_oi_e.doc / Jun-15
Page 45 / 100
7. Start-Up the Unit
The following chapter describes the various options for setting and configuring the unit.
In order to put the unit into operation or to change settings and Parameters, the following measures
must be taken:
 Connect the unit to a 18 … 30 VDC power supply source
 Change the DIL switch slider 3 to its OFF position (unit-state: „Programming Mode“)
 Connect the unit to the OS6.0 operator surface or alternatively to a BG230 programming- and
display unit.
 „Programming Mode“ (DIL switch) only for start-up
 Set all DIL switch sliders to „ON“ after start-up
 Protect the DIL switch sliders after start-up (e. g. by covering with an adhesive tape)
 Normal operation is only permitted when the yellow LED is permanently off
 The safety function of the unit cannot be guaranteed before the commissioning is completed.
Ds230_03a_oi_e.doc / Jun-15
Page 46 / 100
7.1. Setup by PC
The parameterization of the safety device can be done by the operator software OS6.0. The operator
software is included in the delivery on CD and is also available for download on www.motrona.com.
After a successful installation of the operator software OS6.0 and the USB driver (see document
“installation USB driver”) the PC can be connected via a USB cable to the safety device. When
starting the software, the following screen appears:
Parametrization via PC
The functions of the operator software OS6.0 are described in the separate OS6.0 manual.
Ds230_03a_oi_e.doc / Jun-15
Page 47 / 100
7.2. Setup by the Programming Module BG230
The parameterization of the safety device also can be done by the programming module BG230. The
optional display- and programming module BG230 is used for Parameter settings and diagnosis
without a PC. It is easily connectable by plugging onto the front of the safety unit.
Parameterization by BG230
The functions of the BG230 programming- and display unit are described in the BG230 manual.
Ds230_03a_oi_e.doc / Jun-15
Page 48 / 100
7.3. Parameter / Menu Overview
This section provides an overview of the menus and their assignments to the different unit functions.
The menu names are printed bold and associated Parameters are arrayed directly under the menu
names.
No.
000
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
Menu / Parameter
Main Menu
Operational Mode
Sampling Time
Wait Time
F1-F2 Selection
Div. Switch %-f
Div. %-Value
Div. f-Value
Div. Calculation
Div. Filter
Error Simulation
Power-up Delay
Reserved
Reserved
Sensor1 Menu
Direction1
Multiplier1
Divisor1
Position Drift1
Phase Err Count1
Set Frequency1
Reserved
Sensor2 Menu
Direction2
Multiplier2
Divisor2
Position Drift2
Phase Err Count2
Set Frequency2
Reserved
Ds230_03a_oi_e.doc / Jun-15
No.
027
028
029
030
031
032
033
034
035
036
037
038
Menu / Parameter
Preselect Menu
Preselect OUT1.H
Preselect OUT1.L
Preselect OUT2.H
Preselect OUT2.L
Preselect OUT3.H
Preselect OUT3.L
Preselect OUT4.H
Preselect OUT4.L
Preselect REL1.H
Preselect REL1.L
Reserved
Reserved
Page 49 / 100
Continuation “Parameter / Menu Overview”:
No.
039
040
041
042
043
044
045
046
047
048
049
050
051
052
053
054
055
056
057
058
059
060
061
Menu / Parameter
Switching Menu
Switch Mode OUT1
Switch Mode OUT2
Switch Mode OUT3
Switch Mode OUT4
Switch Mode REL1
Pulse Time OUT1
Pulse Time OUT2
Pulse Time OUT3
Pulse Time OUT4
Pulse Time REL1
Hysteresis OUT1
Hysteresis OUT2
Hysteresis OUT3
Hysteresis OUT4
Hysteresis REL1
Startup Mode
Startup Output
Standstill Time
Lock Output
Action Output
Action Polarity
Reserved
Reserved
Ds230_03a_oi_e.doc / Jun-15
No.
062
063
064
065
066
067
068
069
070
071
072
073
074
075
076
077
078
079
080
081
082
083
Menu / Parameter
Command Menu
Input2 Function
Input2 Configuration
Input2 Function
Input2 Configuration
Reserved
Reserved
Serial Menu
Serial Unit No.
Serial Baud Rate
Serial Format
Serial Page
Serial Init
Reserved
Splitter Menu
RS Selector
Reserved
Reserved
Reserved
Analog Menu
Analog Start
Analog End
Analog Gain
Analog Offset
Reserved
Reserved
Page 50 / 100
7.4. Parameter Description
7.4.1. Important notes for DS240 / DS246
When using a DS240 resp.DS246 variant, the following hints must be noted:
Nr.
000
003
013
014
015
016
017
020
021
022
023
024
062
064
074
Parameter
Operational Mode
F1-F2 Selection
Direction1
Multiplier1
Divisor1
Position Drift1
Phase Err Count1
Direction2
Multiplier2
Divisor2
Position Drift2
Phase Err Count2
Input 1 Function
Input 2 Function
RS Selector
Ds230_03a_oi_e.doc / Jun-15
Hints for DS240 /. DS246
Exclusively „Mode = 0“ may be used
Both settings have the same effect
Direction1 and Direction2 must be equal
The setting must be „1“
The setting must be „1“
Position Drift1 and Position Drift2 must be equal
Phase Err Count1 and Phase Err Count2 must be equal
Direction1 and Direction2 must be equal
The setting must be „1“
The setting must be „1“
Position Drift1 and Position Drift2 must be equal
Phase Err Count1 and Phase Err Count2 must be equal
To clear drift errors, Clear Drift 1&2 must be used
To clear drift errors, Clear Drift 1&2 must be used
Both settings have the same effect
Page 51 / 100
7.4.2. Main Menu
No.
000
Parameter
Operational Mode:
Range
0-9
Default
0
Important notes for DS240 / DS246 see chapter 7.4.1
This parameter determines which frequency input ([X6] up to [X10]) is
assigned to the sensor channel Sensor1 and Sensor2. Depending on
the assignment, up to two control inputs (Control1 resp. Control2) for
external commands are available.
Notes and examples for wiring the encoders, control inputs etc. can
be found in chapter 6.5, et seq.
Operational Mode of DS23x:
To ensure the safety function, two independent sensors / encoders are required.
Mode Sensor1
Sensor2
Control1
Control2
0
SinCos encoder at
[X6 | SINCOS IN 1]
SinCos encoder at
[X7 | SINCOS IN 2]
available for
control signals
available for
control signals
1
SinCos encoder at
[X6 | SINCOS IN 1]
HTL encoder (A, B, 90°) available for
[X10 | CONTROL IN]
control signals
Not available!
2
SinCos encoder at
[X6 | SINCOS IN 1]
HTL encoder (A) at
[X10 | CONTROL IN]
available for
control signals
Not available!
3
HTL encoder (A, B, 90°) HTL encoder (A, B, 90°)
Not available!
[X10 | CONTROL IN]
[X10 | CONTROL IN]
Not available!
4
HTL encoder (A, B, 90°) HTL encoder (A) at
[X10 | CONTROL IN]
[X10 | CONTROL IN]
Not available!
Not available!
5
HTL encoder (A) at
[X10 | CONTROL IN]
HTL encoder (A) at
[X10 | CONTROL IN]
Not available!
Not available!
6
SinCos encoder at
[X6 | SINCOS IN 1]
RS422 encoder at
[X9 | RS422 IN 2]
available for
control signals
available for
control signals
7
RS422 encoder at
[X8 | RS422 IN 1]
RS422 encoder at
[X9 | RS422 IN 2]
available for
control signals
available for
control signals
8
RS422 encoder at
[X8 | RS422 IN 1]
HTL encoder (A, B, 90°) available for
[X10 | CONTROL IN]
control signals
Not available!
9
RS422 encoder at
[X8 | RS422 IN 1]
HTL encoder (A) at
[X10 | CONTROL IN]
Not available!
available for
control signals
Operational Mode of DS24x:
To ensure the safety function, a SIL3/PLe certified SinCos sensor resp. encoder is required.
Mode Sensor1
0
Sensor2
SIL3/PLe SinCos encoder Sensor1 and Sensor2
[X6 | SINCOS IN 1]
are internally bridged
Ds230_03a_oi_e.doc / Jun-15
Control1
Control2
available for
control signals
available for
control signals
Page 52 / 100
Continuation “Main Menu”:
No.
001
Parameter
Sampling Time:
The configured value corresponds to the minimum measurement time.
The Parameter is used as a filter in case of irregular frequencies. This
Parameter has a direct influence to the reaction time of the unit. The
setting is valid for both inputs channels.
002
Wait Time:
Defines the period time of the lowest frequency resp. the waiting time
between 2 rising edges, which is detected as „Frequency = 0“ by the
unit.
Range
0,001 - 9,999
(sec.)
Default
0,001
0,010 - 9,999
(sec.)
1,000
All frequencies with a period longer than the Wait Time value will be
interpreted as frequency = 0.
0,010
…
9,999
Frequency = „0“ with frequencies smaller than 100 Hz
Frequency = „0“ with frequencies smaller than 0.1 Hz
The setting is valid for both inputs channels.
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Continuation “Main Menu”:
No.
003
Parameter
F1-F2 Selection (Basic Frequency Selection):
Range
0-1
Important notes for DS240 / DS246 see chapter 7.4.1
This Parameter determines, which of both input frequencies of sensor1
or sensor2 (see parameter 000) is monitored and processed as basic
frequency.
The basic frequency selection affects the following outputs:
- Analog Output
- Control Outputs
- Relay Outputs
And thus the following menus:
- preselected thresholds in the Preselect Menu (see chapter 7.4.5)
- switching behaviors in the Switching Menu (see chapter 7.4.6)
- analog output in the Analog Menu (see chapter 7.4.10)
0
1
Frequency of sensor1 serves as basic frequency
Frequency of sensor2 serves as basic frequency
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Default
0
Continuation “Main Menu”:
No.
004
Parameter
Div. Switch %-f (Divergence switching point %-Hz):
The unit constantly compares the frequencies of sensor1 and
Sensor2 to the adjusted, maximum allowed divergence. Usually the
comparison works percentages. Application-specific with lower
frequencies a percentages comparison can be problematic, so that
a direct monitoring of the difference frequency in Hz can deliver
better results.
Range
0 - 999.99
(Hz)
Default
100.00
0 - 100
(%)
10
0 - 99,99
(Hz)
30,00
0-1
0
This Parameter allows to define a limit. When undershooting the
adjusted value the comparison will proceed no more percentages,
but absolute in Hz (see parameter 006 and 006).
005
Div. %-Value (maximum Divergence %):
Defines the maximum allowed percentage divergence between the
frequencies of sensor1 and sensor2.*
If this value is exceeded, the unit switches to an error status
(see parameter 004).
006
Div. f-Value (maximum Divergence Hz):
Defines the maximum allowed absolute divergence in Hz between
the frequencies of sensor1 and sensor2.*
If the adjusted value is exceeded, the unit switches to an error
status (see parameter 004).
007
Div. Calculation (Divergence Calculation Mode):
Defines a reference value in order to determine the percentage
divergence.*
0:

1:

reference value is the frequency of sensor1:
(%) = (sensor1 - sensor2) : sensor1 x 100%
reference value is the frequency of sensor2:
(%) = (sensor2 - sensor1) : sensor1 x 100%
)* The divergence calculation depends on the frequency-scaling
of sensor1 and sensor2 (see chapter 7.4.3 resp. 7.4.4)
Ds230_03a_oi_e.doc / Jun-15
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Continuation “Main Menu”:
No.
008
Parameter
Div. Filter:
Range
0 - 20
Default
1
The exact function will be described soon!!!
This digital filter parameter evaluates the divergence between
sensor1 and sensor2.
0
10
20
The filter is not active:
The unit reacts immediately to each frequency
deviation.
Medium filter:
The unit tolerates temporary deviations and
fluctuations, e. g. caused from torsion or mechanical
vibrations and reacts delayed to deviations between
both input frequencies.
Strongest filter:
The unit tolerates temporary deviations and
fluctuations, e. g. caused from torsion or mechanical
vibrations and reacts with a very long delay to
prolonged deviations between both input frequencies.
Ds230_03a_oi_e.doc / Jun-15
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Continuation „Main Menu“:
No.
009
Parameter
Error Simulation:
Range
0-2
Default
1
1 - 1,000
(sec.)
0,100
This Parameter is only allowed in the “Programming Mode”
(see chapter 5.11) and serves only for test purposes during the
commissioning procedure. It allows to simulate and prevent the
following error messages:
0
1
2
Error state:
Sets the unit into error status. By using this Parameter
it is possible to check, if the entire follow-up system
reacts correctly at error status.
Normal state:
Before exiting the “Programming Mode”,
the Parameter always must be set to 1.
Error clearing:
All errors reported by the unit will be reset.
A direct changeover between 0 and 2 should be avoided
After the test, this parameter must be reset to the "Default".
010
Power-up Delay:
A delay time setting is recommended to ensure for all connected
encoders a safely power up and enough time for stabilization after
switching the encoder supply. The signal evaluation will start only
after the selected delay.
011
012
Reserved
Reserved
The safety function of the unit cannot be guaranteed before the commissioning is completed.
Ds230_03a_oi_e.doc / Jun-15
Page 57 / 100
7.4.3. Sensor1 Menu
No.
013
Parameter
Direction1:
Range
0-1
Default
0
1 - 10 000
1
1 - 10 000
1
Important notes for DS240 / DS246 see chapter 7.4.1
Parameter to assign a direction for Sensor1
0
1
No changes
Changes the sign of the direction
This allows to reverse the direction of Sensor1 in order to adapt
Sensor1 to the direction of Sensor2.
For SIN / COS or A, B input signals, the primary direction is defined
by the signal phase shifting. With single-channel HTL signals (only
channel A) the direction can be defined by using a static signal at
the channel B input.
The direction selection affects the following outputs:
- Analog Output
- Control Outputs
- Relay Outputs
And thus the following menus:
- preselected thresholds in the Preselect Menu (see chapter 7.4.5)
- switching behaviors in the Switching Menu (see chapter 7.4.6)
- analog output in the Analog Menu (see chapter 7.4.10)
014
Multiplier1 (proportional pulse scaling factor):
Is used to modulate the frequencies of Sensor 1 and Sensor2.
This scaling affects only the calculation of the divergence
(see parameter 004, et seq.).
015
Divisor1 (reciprocal pulse scaling factor):
To adjust the frequencies of sensor1 and sensor2.
This scaling affects only the calculation of the divergence
(see parameter 004, et seq.).
When using two encoders with differing pulse rates or in case of a mechanical reduction between
both encoders, the higher frequency must be converted to the lower frequency by using the
scaling factors (see chapter 8.).
Ds230_03a_oi_e.doc / Jun-15
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Continuation “Sensor1 Menu”:
No.
016
Parameter
Position Drift1 (drift monitoring at standstill):
Range
0 - 100 000
Default
0
1- 1 000
10
-500 000.0
500 000.0
(Hz)
0
Important notes for DS240 / DS246 see chapter 7.4.1
This Parameter handles drift movements at standstill. If the period
time of the input frequency exceeds the adjusted „Wait-Time“ (see
parameter 002), the sensor is assigned to frequency = 0, even if a
slow drift movement is present.
In case of an illegal drift, this Parameter allows to preset an error
threshold (symmetrical position window +/- xxx pulses). The
monitoring is only performed at standstill and begins at position 0,
immediately when frequency = 0 is detected.
0
xxx
017
Drift monitoring not active
An error message appears, when the position is drifting
out of the adjusted window of +/- xxx pulses (single
edge evaluation).
Phase Err Count1 (faulty pulse counting limit):
Important notes for DS240 / DS246 see chapter 7.4.1
The DS unit is able to detect incorrect pulse sequences as well as
faulty phase positions.
The error status will be released if the adjusted number of faulty
pulses is exceeded.
Incorrect pulses can be caused by faulty wirings, EMC-problems,
incorrect mode settings, when turn up the encoder supply or when
reverse the direction Parameter.
018
Set Frequency1 (simulation of a fixed encoder frequency):
This Parameter is used for test purposes and allows to substitute
the real encoder frequency by a fixed frequency.
The setting will take effect, if
- the unit state (DIL switch) = “Programming Mode” and
- the setting of Parameter 62 = 7 (see also chapter 7.4.7)
019
Reserved
When using two encoders with differing pulse rates or in case of a mechanical reduction between
both encoders, the higher frequency must be converted to the lower frequency by using the
scaling factors (see chapter 8.).
Ds230_03a_oi_e.doc / Jun-15
Page 59 / 100
7.4.4. Sensor2 Menu
No.
019
Parameter
Direction2:
020
Multiplier2:
021
Divisor2:
022
Position Drift2:
023
Phase Err Count2:
024
Set Frequency2:
025-026
Reserved
The description of the
sensor2 Parameters is
identically with the sensor1
menu, but all settings are
related to sensor2 which is
specified by the „Operation
Mode“.
Range
0-1
Default
0
1- 10 000
1
1 - 10 000
1
0 - 100 000
0
1 - 1 000
10
-500 000.0
500 000.0 (Hz)
0
When using 2 encoders with differing pulse rates or in case of a mechanical reduction
between both encoders, the higher frequency must be converted to the lower frequency
by using the scaling factors (see chapter 8.).
Ds230_03a_oi_e.doc / Jun-15
Page 60 / 100
7.4.5. Preselect Menu
This menu is used to set the switching points of the following outputs:
- 1 x relay output [X1 | RELAY OUT]
- 4 x control output [X2 | CONTROL OUT]
All settings are related to the selected basic frequency (see parameter 003) considering to the
adjusted scaling factor of the basic sensor (see chapter 7.4.3).
There are two separate switching points for each output, which allows e. g. to define the limit
values for the “set-up mode” and “production mode”.
A switchover between the switching points „High“ and „Low“ can only be released by an external
command, resp. by using one of the both control inputs at terminal [X10 | CONTROL IN]. The change
will affect all outputs! Therefore the function „Preselection Change“ must be assigned to an unused
input (see chapter 7.4.7 / Parameter 062 = 13). A switchover is only possible if the control input
Control1 or Control2 in the selected "Operational Mode" (Parameter 000) is available (see chapter
6.5, et seq.).
Index „.H“ stands for „High“ and requires a higher limit value.
Index „.L“ stands for „Low“ and requires a lower limit value.
Ds230_03a_oi_e.doc / Jun-15
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„Preselect Menu“
No.
027
Parameter
Preselect OUT1.H:
Upper switching point of output OUT1 [X2:1-2]
028
Preselect OUT1.L:
Lower switching point of output OUT1 [X2:1-2]
029
Preselect OUT2.H:
Upper switching point of output OUT2 [X2:3-4]
030
Preselect OUT2.L:
Lower switching point of output OUT2 [X2:3-4]
031
Preselect OUT3.H:
Range
Default
10 000
-500 000.0
500 000.0
20 000
(Hz)
30 000
(see basic
frequency,
Parameter 003)
40 000
50 000
Upper switching point of output OUT3 [X2:5-6]
032
Preselect OUT3.L:
60 000
Lower switching point of output OUT3 [X2:5-6]
033
Preselect OUT4.H:
70 000
Upper switching point of output OUT4 [X2:7-8]
034
Preselect OUT4.L:
80 000
Lower switching point of output OUT4 [X2:7-8]
035
Preselect REL1.H:
1 000
Upper switch-point of the relay output [X1:1-2]
036
Preselect REL1.L:
2 000
Lower switching point of the relay output [X1:1-2]
037
038
Reserved
Reserved


The upper switching point (index .H) is only active, if no error can be detected and if an
external signal is triggered to the control input according to chapter 7.4.7.
The operator has to assign the values to the switch-points correctly.
The “High” value must always be higher than the “Low” value.
Ds230_03a_oi_e.doc / Jun-15
Page 62 / 100
7.4.6. Switching Menu
This menu is used to set the switching conditions of the following outputs:
- 1 x relay output [X1 | RELAY OUT]
- 4 x control output [X2 | CONTROL OUT]
The following form of writing is used:
|f|
= absolute value of the basic frequency (see parameter 003)
|Preselection| = absolute value of the switching point (see parameter 027, ff.)
f
= direction dependent, direction signed basic frequency (see parameter 003)
Preselection = direction dependent, direction signed switching point (see parameter 027, ff.)
Additional features which can be assigned to the output:
{S}
= self-locking function (see parameter 057 – Lock Output)
{H}
= switching hysteresis (see parameter 049, ff. – Hysteresis)
{A}
= start up delay (see parameter 055 – Startup Mode)



When using Switch Mode 2 or 6, a hysteresis is useful in order to avoid "bouncing" of
the outputs at the switching point.
When using Switch Mode 7 or 8, the specified standstill-time (see parameter 056) must
be higher than the adjusted wipe period (see parameter 044, ff.). This is helpful to
prevent a breakdown of the wipe signal before the wipe period has been elapsed.
With negative measuring values and presets a higher numerical value is smaller than
a lower numerical value, thus e. g. -1000 < -500.
Ds230_03a_oi_e.doc / Jun-15
Page 63 / 100
„Switching Menu“:
No.
039
Parameter
Switch Mode OUT1 (switching condition for OUT1):
0
1
2
3
4
5
6
040
|f| >= |Preselection|
Output switches in event of overspeed
|f| <= |Preselection|
Output switches in event of underspeed
|f| == |Preselection|
Output switches in event of leaving the
frequency band (Preselection +/- Hysteresis)
Standstill (see parameter 056)
Output switches in event of standstill
f >= Preselection
Output switches in event of overspeed
May only be used with positive preselection
values!
f <= Preselection
Output switches in event of underspeed
May only be used with positive preselection
values!
f == Preselection
Output switches in event of leaving the
frequency band (Preselection +/- Hysteresis)
Only used with positive preselection values!
7
f>0
8
f<0
Range
Default
0-8
0
0-8
0
0-8
0
{S, H}
{S, H, A}
{S, H, A}
{S, H}
{S, H, A}
{S, H, A}
Output switches, if a positive frequency (e.g.
clockwise direction) is detected. The directional
information will be deleted immediately when
„standstill“(Parameter 056) is detected.
Output switches, if a negative frequency (e.g.
anticlockwise direction) is detected. The
directional information will be deleted
immediately when „standstill“(Parameter 056)
is detected.
Switch Mode OUT2 (switching condition for OUT2):
Settings are analogous to „Switch Mode OUT1“
041
Switch Mode OUT3 (switching condition for OUT3):
Settings are analogous to „Switch Mode OUT1“
042
Switch Mode OUT4 (switching condition for OUT4):
Settings are analogous to „Switch Mode OUT1“
Ds230_03a_oi_e.doc / Jun-15
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No.
043
Parameter
Switch Mode REL1 (switching condition for relay output):
0
1
2
3
4
5
6
|f| >= |Preselection|
Output switches in event of overspeed
|f| <= |Preselection|
Output switches in event of underspeed
|f| == |Preselection|
Output switches in event of leaving the
frequency band (Preselection +/- Hysteresis)
Standstill (see parameter 056)
Output switches in event of standstill
f >= Preselection
Output switches in event of overspeed
May only be used with positive preselection
values!
f <= Preselection
Output switches in event of underspeed
May only be used with positive preselection
values!
f == Preselection
Output switches in event of leaving the
frequency band (Preselection +/- Hysteresis)
Only used with positive preselection values!
7
f>0
8
f<0
Range
0-8
Default
0
{S, H}
{S, H, A}
{S, H, A}
{S, H}
{S, H, A}
{S, H, A}
Output switches, if a positive frequency (e.g.
clockwise direction) is detected. The directional
information will be deleted immediately when
„standstill“(Parameter 056) is detected.
Output switches, if a negative frequency (e.g.
anticlockwise direction) is detected. The
directional information will be deleted
immediately when „standstill“(Parameter 056)
is detected.



When using Switch Mode 2 or 6, a hysteresis is useful in order to avoid "bouncing" of
the outputs at the switching point.
When using Switch Mode 7 or 8, the specified standstill-time (see parameter 056) must
be higher than the adjusted wipe period (see parameter 044, ff.). This is helpful to
prevent a breakdown of the wipe signal before the wipe period has been elapsed.
With negative measuring values and presets a higher numerical value is smaller than
a lower numerical value, thus e. g. -1000 < -500.
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Continuation “Switching Menu”:
No.
044
Parameter
Pulse Time OUT1 (Wipe Signal Period of OUT1):
0:
static wipe signal
≠0: wipe signal period in seconds
045
Pulse Time OUT2 (Wipe Signal Period of OUT2):
Range
0 - 9.999
(sec.)
Default
0
Settings are analogous to „Pulse Time OUT1“
046
Pulse Time OUT3 (Wipe Signal Period of OUT3):
Settings are analogous to „Pulse Time OUT1“
047
Pulse Time OUT4 (Wipe Signal Period of OUT4):
Settings are analogous to „Pulse Time OUT1“
048
Pulse Time REL1 (Wipe Signal Period of the relay):
Settings are analogous to „Pulse Time OUT1“, but min. 0.025 sec.


049
The minimum wipe period of the control outputs is 1 msec.
The minimum wipe period of the relay is 25 msec.
If a wipe signal is adjusted (Parameter 044, ff.) no self-locking function
(Parameter 057) can be assigned to the respective output.
Hysteresis OUT1:
Percental hysteresis of the adjusted switching point
(see parameter 027 and 028)
050
Hysteresis OUT2:
0- 100.0
(%)
0
Percental hysteresis of the adjusted switching point
(see parameter 029 and 030)
051
Hysteresis OUT3:
Percental hysteresis of the adjusted switching point
(see parameter 031 and 032)
052
Hysteresis OUT4:
Percental hysteresis of the adjusted switching point
(see parameter 033 and 034)
053
Hysteresis REL1:
Percental hysteresis of the adjusted switching point
(see parameter 035 and 036)


Due to the variance of the frequency measurement an output-bouncing can occur
around the limit value. This can be prevented by setting a hysteresis. A reasonable
hysteresis value is approximately 1%.
The setting of a hysteresis is only possible when the parameter "Switch Mode OUT1" is
between 0 and 6. (see parameter 039 and following., marking {H})
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Continuation “Switching Menu”:
No.
054
Parameter
Start-up Mode (start-up delay time window):
Range
0-9
Default
0
0 - 31
0
Delay time window until the monitoring function is activated. Only
useful in combination with switching mode 1 and 5 (see chapter 7.4.6).
To use the start-up delay, it must be assigned to an output (see
parameter 055).
The start-up delay will be activated:
a) with next power-up
b) always when after standstill a frequency is detected again
0
1
2
3
4
5
6
7
8
9
no start-up delay
start-up delay 1 second
start-up delay 2 seconds
start-up delay 4 seconds
start-up delay 8 seconds
start-up delay 16 seconds
start-up delay 32 seconds
start-up delay 64 seconds
start-up delay 128 seconds
automatically, until the value has been exceeded
for the first time (see chapter 7.4.5)
The defined delay time window is valid for all outputs
(see parameter 055).
055
Startup Output (assignment of a start-up delay to outputs):
By using a 5 bit binary code the start-up delay function can be assigned
to the outputs. Settings see below:
Output:
RELAY
OUT4
OUT3
OUT2
OUT1
Bit
5
4
3
2
1
Binary:
10000
01000
00100
00010
00001
Value:
16
8
4
2
1
Example:
A setting of „17“ (binary 10001) means that a start-up delay is assigned
to OUT1 and to the relay-output.


During the start-up delay no frequency monitoring resp. frequency comparison
is processed!
The setting of a start up delay time is only possible when the parameter "Switch Mode
OUT1" is 1, 2, 5 or 6. (see parameter 039 and following., marking {A})
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Continuation “Switching Menu”:
No.
056
Parameter
Standstill Time (delay time until „standstill“):
This parameter defines the delay time until the unit detects „standstill“
after detecting „frequency = 0“.
057
Prior condition is that both input frequencies are detected as „Zero“
(f1, 2 = 0). From that moment, the standstill period runs off and indicates
„Standstill“ when elapsed.
Lock Output (assignment of a lock-function to an output):
Range
0 - 9.999
(sec.)
Default
0
0 - 63
0
The assignment of a lock-function to an output can be adjusted by
using a 6 bit binary code as follows:
Output:
(*)
RELAY OUT4
OUT3
OUT2
OUT1
Bit
6
5
4
3
2
1
Binary: 100000 010000 001000 000100 000010 000001
Value:
32
16
8
4
2
1
Bits 1 to 5 are used to assign the lock function to the respective
outputs. The highest valued bit 6 (*) determines if a locked output can
be released exclusively by an external input signal (bit 6 = 0) - see
chapter 7.4.7 - or additionally by an automatic reset when “Standstill”
is indicated (bit 6 = 1).
Example:
An adjustment of 17 (binary 10001) means that a lock is assigned to
output Out1 and to the relay, which can be released exclusively by an
external input signal (see chapter 7.4.7).
Further the adjustment 49 (binary 110001) means that the lockfunctions of OUT1 and the relay are deleted additionally when
„Standstill“ is detected.


If a wipe signal is adjusted (Parameter 044, ff.) no self-locking function
(parameter 057) can be assigned to the respective output.
The setting of a lock output function is only possible when the parameter "Switch
Mode OUT1" is between 0 and 6. (see parameter 039 and following., marking {S})
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Continuation “Switching Menu”:
No.
058
Parameter
Action Output (output selection for overwriting):
Range
0 - 31
Default
0
The function to set fixed output conditions by overwriting is only
effective in the “Programming Mode” (see chapter 5.11). It is used for
test purposes and allows to force each output to a defined switching
condition.
The „Action Output“ parameter selects the outputs to be tested.
The next Parameter „Action Polarity“ (parameter 059) is used to assign
the desired switching conditions to the selected outputs.
The outputs are selectable by using a 5 bit binary code:
Output:
Bit
Binary:
Value:
RELAY
5
10000
16
OUT4
4
01000
8
OUT3
3
00100
4
OUT2
2
00010
2
OUT1
1
00001
1
Example:
A setting of 14 (binary 01110) means that the outputs OUT2, OUT3 and
OUT4 are selected for overwriting.
REL
OUT4
OUT3
OUT2
OUT1
0
1
1
1
0
No overwriting
Status see Action Polarity (parameter 059)
Status see Action Polarity (parameter 059)
Status see Action Polarity (parameter 059)
No overwriting
After the test, this parameter must be reset to the "Default".
The safety function of the unit cannot be guaranteed before the commissioning is completed.
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Continuation “Switching Menu”:
No.
059
Parameter
Action Polarity (setting the output conditions):
Range
0 - 511
Default
0
This setting-function is only effective in the “Programming Mode” (see
chapter 5.11) and requires a selection of the corresponding outputs
(see parameter 058).
For security reasons the 4 digital outputs are complementary, which
means that each output has one direct track and an inversed one
(marked by a slash „/“). During normal operation both tracks generally
must have opposite conditions, but in the test-mode arbitrary outputconditions can be simulated.
The output-conditions are assignable by a 9 bit binary code:
OUT:
Bit
Value:
REL
9
256
4
8
128
/4
7
64
3
6
32
/3
5
16
2
4
8
/2
3
4
1
2
2
/1
1
1
Example:
A setting of 275 (binary 1 0001 0011) causes the following output
conditions (from left to right):
REL
OUT4
/OUT4
OUT3
/OUT3
OUT2
/OUT2
OUT1
/OUT1
1
0
0
0
1
0
0
1
1
Contact closed
Low
Low
Low
High
Low
Low
High
High
After the test, this parameter must be reset to the "Default".
060
061
Reserved
Reserved
The safety function of the unit cannot be guaranteed before the commissioning is completed.
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7.4.7. Control Menu
This chapter describes the features and configuration options of the control inputs. Depending on
the operating mode (see chapter 7.4.1), up to two HTL/PNP control inputs (Control1 and Control2) are
available at terminal [X10 | CONTROL IN].
Control1
Control2
X10 | CONTROL IN, Pin 2, 3
X10 | CONTROL IN, Pin 4, 5
A control input can only be used, if Control1 or Control2 (see chapter 6.5, et seq.) is available in the
selected operation mode.
For security reasons both control inputs are complementary. The switching conditions (active HIGH
or active LOW) can be defined by parameter 063.
Basically always the complementary signal of the direct input must be applied to the inverted input.
All other conditions are invalid and will not be accepted by the unit. Valid conditions are:
Control1
Control2
X10 | CONTROL IN, Pin 2, HIGH
X10 | CONTROL IN, Pin 2, LOW
X10 | CONTROL IN, Pin 4, HIGH
X10 | CONTROL IN, Pin 4, LOW
X10 | CONTROL IN, Pin 3, LOW
X10 | CONTROL IN, Pin 3, HIGH
X10 | CONTROL IN, Pin 5, LOW
X10 | CONTROL IN, Pin 5, HIGH
If the commands „Set Frequency“ and „Freeze Frequency“ are activated simultaneously by the
external control inputs, the function „Set Frequency“ has priority.
Ds230_03a_oi_e.doc / Jun-15
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„Control Menu“
No. Parameter
062 Input 1 Function (assigns a control function to input „Control1“):
Range
0 - 16
Default
0
Important notes for DS240 / DS246 see chapter 7.4.1
The switching conditions (active HIGH or active LOW) can be defined by
parameter 063.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
No function assigned
Release lock of output „OUT1“
Release lock of output „OUT2“
Release lock of output „OUT3“
Release lock of output „OUT4“
Release lock of output „RELAY“
Release all output locks together
Set Frequency1 (see parameter 018)
Frequency simulation of Sensor1 (see parameter000)
Set Frequency2 (see parameter 025)
Frequency simulation of Sensor2 (see parameter000)
Set Frequency12 (see parameter 018 und 025)
Frequency simulation of Sensor1 und Sensor2
Freeze Frequency1
Freezes the actual encoder frequency of Sensor1
Freeze Frequency2
Freezes the actual encoder frequency of Sensor2
Freeze Frequency12
Freezes the encoder frequency of Sensor1 and Sensor2
Preselection Change (see chapter 7.4.5)
Switchover between the upper and lower switching
point. Takes effect to all outputs.
Clear Drift1 (see parameter 016)
Clears the counter of position drift 1.
Clear Drift2 (see parameter 023)
Clears the counter of position drift 2
Clear Drift12 (see parameter 016 und 023)
Clears both counters (position drift 1 and 2)
[dyn]
[dyn]
[dyn]
[dyn]
[dyn]
[dyn]
[stat]
[PRG]
[stat]
[PRG]
[stat]
[PRG]
[stat]
[PRG]
[stat]
[PRG]
[stat]
[PRG]
[stat]
[dyn]
[dyn]
[dyn]
[dyn] = dynamic function if a rising edge appears at the input
[stat] = static permanent function
[PRG] = function only in the “Programming Mode” active

If the commands „Set Frequency“ and „Freeze Frequency“ are activated simultaneously by
the external control inputs, the function „Set Frequency“ has priority.

The safety function of the unit cannot be guaranteed before the commissioning is completed.
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Continuation „Control Menu“
No. Parameter
063 Input 1 Config (switching condition of input Control1):
0
1
2
3
Range
0-3
Default
0
0 - 16
0
0-3
0
static function,
active LOW: [X10:2] = Lo, [X10:3] = Hi
static function,
active HIGH: [X10:2] = Hi, [X10:3] = Lo
dynamic function,
active when moving from HIGH to LOW [X10:2]
and simultaneously moving from LOW to HIGH [X10:3]
dynamic function,
active when moving from HIGH to LOW [X10:2]
and simultaneously moving from LOW to HIGH [X10:3]
064 Input 2 Function (assigns a control function to input Control2):
Identical functions to Parameter 062, but for input Control2
065 Input 2 Config (switching condition of the input Control2):
Identical functions to Parameter 063, but for input Control2
066 Reserved
067 Reserved
The safety function of the unit cannot be guaranteed before the commissioning is completed.
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7.4.8. Serial Menu
No.
068
Parameter
Serial Unit No. (assigns a serial unit number):
Range
11 - 99
Default
11
0 - 10
0
0-9
0
The devices can be assigned by unit numbers between 11 and 99
(default setting = 11).
Unit numbers which contain a “0“ are forbidden because these are used
for group- or bulk-addressing.
069
Serial Baud Rate (serial transmission speed):
0:
1:
2:
3:
4:
5:
6:
7:
8:
9:
10:
070
9 600
4 800
2 400
1 200
600
19 200
38 400
56 000
57 200
76 800
115 200
Baud
Baud
Baud
Baud
Baud
Baud
Baud
Baud
Baud
Baud
Baud
Serial Format (format of the serial data):
0:
1:
2:
3:
4:
5:
6:
7:
8:
9:
7 data bits,
7 data bits,
7 data bits,
7 data bits,
7 data bits,
7 data bits,
8 data bits,
8 data bits,
8 data bits,
8 data bits,
parity even,
parity even,
parity odd,
parity odd,
no parity*,
no parity*,
parity even,
parity odd,
no parity*,
no parity*,
1 stop bit
2 stop bits
1 stop bit
2 stop bits
1 stop bit
2 stop bits
1 stop bit
1 stop bit
1 stop bit
2 stop bits
*) „no parity“: no secure data transmission guaranteed.
„Parity even“ or „Parity odd“ must be set for a secure data transmission.
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Continuation „Serial Menu“:
No.
071
Parameter
Serial Page (serial page number of a variable):
Range
0 - 11
Default
0
0-1
0
The Parameter serves only for diagnosis purposes by the manufacturer.
072
Serial Init:
This parameter determines the baud rate (see parameter 069) for the
transmission of the initialization values to the operator surface OS6.0
respectively to the BG230 programming and display unit.
0
The initialization values will be transmitted with 9600
baud. After that, the unit returns back to the baud rate
set by the user.
1
The initialization values will be transmitted with the user
setting. After that, the unit continues with this baud rate.
With settings higher than 9600 baud the duration of the initialization
can be shortened.
073
Reserved
Ds230_03a_oi_e.doc / Jun-15
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7.4.9. Splitter Menu
(Looping of Sensor Signals for further Target Units)
The Splitter function is only integrated in DS230 and DS240.
No.
074
Parameter
RS Selector (determination of the RS422 output source):
Range
0-1
Default
0
Important notes for DS240 / DS246 see chapter 7.4.1
This parameter defines which input frequency (sensor1 or sensor2) is
exported at terminal [X4 | RS422 OUT].
Which input is assigned to which channel (sensor1 or sensor2) is set in
the operating mode (see chapter 7.4.2 / parameter 000).
0
1
Sensor1
A copy of the sensor1 frequency appears at terminal
[X4 | RS422 OUT] (as specified by parameter 000)
Sensor2
A copy of the sensor2 frequency appears at terminal
[X4 | RS422 OUT] (as specified by parameter 000)
Independent from the input signal, always incremental RS422 squarewave pulses are generated.
075
076
077
Reserved
Reserved
Reserved
Ds230_03a_oi_e.doc / Jun-15
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7.4.10. Analog Menu
(Analog Output Configuration)
The setting of the F1-F2-Selection (Parameter 003) determines, which frequency (sensor1 or sensor2) is
used to generate the analog output signal.
No.
078
Parameter
Analog Start (initial value of the conversion range in Hz):
Defines the initial frequency, at which the analog output should set
its initial value of 4 mA.
079
Analog End (final value of the conversion range in Hz):
Defines the final frequency, at which the analog output should set
its final value of 20 mA.
080
Analog Gain (gain of the D/A converter in %):
With a setting of 100% the frequency curve between „Analog
Start“ and „Analog End“ equates to the whole stroke from 4 mA to
20 mA (thus 16 mA).
Range
-500 000.0
500 000.0
(Hz)
Default
0
100 000
1 - 1 000
(%)
100
With a setting of e. g. 50 % the stroke would be only 8 mA and the
analog output only a value of 4 + 8 = 12 mA when reaching
„Analog End“.
mA
75
50
25
Analog Swing %
20
16
12
8
0
4
0
Analog Start (Hz)
081
Analog Offset (fine adjustment of the zero point in µA):
Accurate adjustment of the analog offset within a fine range.
082
Analog End (Hz)
-25 - 25
(µA)
Reserved
Ds230_03a_oi_e.doc / Jun-15
Page 77 / 100
0
8. Start-Up the Plant

„Programming Mode“ (DIL switch) only for start-up


Set all DIL switch sliders to „ON“ after start-up
Protect the DIL switch sliders after start-up
(e. g. by covering with an adhesive tape)
Normal operation is only permitted when the yellow LED is permanently off

8.1. Cabinet installation
 The unit must be in a mechanically and technically perfect condition.
 The unit must be snapped onto a 35 mm DIN rail (according to EN 60715) by using the clip at
the rear.
 It must be ensured that the permissible environmental conditions of the specification are met
accordingly.
 All wirings must be executed in accordance with the general provisions for wiring
(see www.motrona.com).
In order to prevent simultaneous damages to the cables by external influences,
the encoder resp. sensor lines must be kept physically separate from one another.
Ds230_03a_oi_e.doc / Jun-15
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8.2. Parametrization
In order to ensure proper functionality the parameters must be set appropriate values. The next two
chapters 8.2.1 and 8.2.2 will describe important parameters, which must be set or checked in each
case.
The parameters of the subsequent chapters must be set or checked only when the respective
outputs are used.
8.2.1. Basic Settings
The following parameters must be set or checked in each case. Important basic settings of the
device will be defined here. These parameters settings will also influence other parameters, the
device function and the error detection time.
No.
Parameter
000
001
002
003
010
016
017
023
024
056
Operational Mode
Sampling Time
Wait Time
F1-F2 Selection
Power-up Delay
Position Drift1
Phase Err Count1
Position Drift2
Phase Err Count2
Standstill Time
Notice
8.2.2. Sensor1 and Sensor 2 Settings (Divergence)
The following parameters must be set or checked in each case. Important adjustments to calibrate
both sensor frequencies (Sensor1 and Sensor2) are defined here. These parameters settings will
also influence other parameters, the device function and the error detection time.
No.
Parameter
004
005
006
007
008
013
014
015
020
021
022
Div. Switch %-f
Div. %-Value
Div. f-Value
Div. Calculation
Div. Filter
Direction1
Multiplier1
Divisor1
Direction2
Multiplier2
Divisor2
Ds230_03a_oi_e.doc / Jun-15
Notice
Page 79 / 100
8.2.3. SinCos Output Settings
Depending on the version and the operational mode, the unit is equipped with a SinCos output.
The SinCos output cannot be configured.
8.2.4. RS422 Output Settings
These parameter may be used only, if the RS422 output is used.
The RS422 output essentially depends on the following parameters:
No.
Parameter
000
074
Operational Mode
RS Selector
Notice
8.2.5. Analog Output Settings
These parameter may be used only, if the analog output is used.
The analog output essentially depends on the following parameters:
No.
Parameter
000
003
078
079
080
081
Operational Mode
F1-F2 Selection
Analog Start
Analog End
Analog Gain
Analog Offset
Ds230_03a_oi_e.doc / Jun-15
Notice
Page 80 / 100
8.2.6. Control Output Settings
These parameter may be used only, if control outputs are used.
The control outputs are essentially dependent on the following parameters:
OUT1:
No.
Parameter
000
003
027
028
039
044
049
054
055
057
062
063
064
065
Operational Mode
F1-F2 Selection
Preselect OUT1.H
Preselect OUT1.L
Switch Mode OUT1
Pulse Time OUT1
Hysteresis OUT1
Startup Mode
Startup Output
Lock Output
Input1 Function
Input1 Configuration
Input2 Function
Input2 Configuration
Notice
OUT2:
No.
Parameter
000
003
029
030
040
045
050
054
055
057
062
063
064
065
Operational Mode
F1-F2 Selection
Preselect OUT2.H
Preselect OUT2.L
Switch Mode OUT2
Pulse Time OUT2
Hysteresis OUT2
Startup Mode
Startup Output
Lock Output
Input1 Function
Input1 Configuration
Input2 Function
Input2 Configuration
Ds230_03a_oi_e.doc / Jun-15
Notice
Page 81 / 100
Continuation „Control Output Settings“:
OUT3:
No.
Parameter
000
003
031
032
041
046
051
054
055
057
062
063
064
065
Operational Mode
F1-F2 Selection
Preselect OUT3.H
Preselect OUT3.L
Switch Mode OUT3
Pulse Time OUT3
Hysteresis OUT3
Startup Mode
Startup Output
Lock Output
Input1 Function
Input1 Configuration
Input2 Function
Input2 Configuration
Notice
OUT4:
No.
Parameter
000
003
033
034
042
047
052
054
055
057
062
063
064
065
Operational Mode
F1-F2 Selection
Preselect OUT4.H
Preselect OUT4.L
Switch Mode OUT4
Pulse Time OUT4
Hysteresis OUT4
Startup Mode
Startup Output
Lock Output
Input1 Function
Input1 Configuration
Input2 Function
Input2 Configuration
Ds230_03a_oi_e.doc / Jun-15
Notice
Page 82 / 100
8.2.7. Relay Output Settings
These parameter may be used only, if relay outputs are used.
The relay outputs are essentially dependent on the following parameters:
No.
Parameter
000
003
035
036
043
048
053
054
055
057
062
063
064
065
Operational Mode
F1-F2 Selection
Preselect REL1.H
Preselect REL1.L
Switch Mode REL1
Pulse Time REL1
Hysteresis REL1
Startup Mode
Startup Output
Lock Output
Input1 Function
Input1 Configuration
Input2 Function
Input3 Configuration
Notice
8.2.8. Test Parameters
The parameters below may be used only for test purposes. After the tests, these parameters must
be set back to "default" values.
No.
Parameter
009
018
025
058
059
Error Simulation
Set Frequency1
Set Frequency2
Action Output
Action Polarity
Ds230_03a_oi_e.doc / Jun-15
Notice
Page 83 / 100
8.3. Preparation before first start-up
Before first start-up
 the unit must be in a perfect technical condition, properly installed and wired
 the unit must be set to the unit-state “Programming Mode” by setting the DIL switch slider 3
“OFF”
 the unit must be connected via the USB port to a PC / notebook or alternatively to an
optional BG320 programming- and display unit
 the operator surface OS6.0 must be installed correctly and running on the PC
 all Parameters must be set to correct values
 Commissioning may only be performed by qualified personnel.
 The machine / equipment must be protected from unauthorized persons, because
undefined states of the machine / plant can occur during the first start up procedure.
 The machine must be securely mounted and ready to operate.
 The safety function of the unit cannot be guaranteed before the commissioning is
completed.
Ds230_03a_oi_e.doc / Jun-15
Page 84 / 100
8.4. Checklist for Parameter Settings
General settings:
1. Does Parameter 000 (Operational Mode) correspond to the selected encoder types?
2. Are correct preset values defined in the „Preselection Menu“ (Parameter 027, et seq.)?
3. Are all outputs and relays adjusted in accordance to the demanded switching conditions?
(see chapter …)
Optional settings:
1. Are the switching characteristics and command assignments for the HTL inputs defined?
2. Is the source input for the RS422 splitter output selected (see parameter 074)?
3. Is the analog output scaled with a start- and an end-value (see parameter 078, 079)?
8.5. Definition of the Directions
In order to define the directions, the machine must move resp. turn to its working direction. The
frequencies of sensor 1 and 2 are indicated in the “Monitor” window of the operator surface. The
direction of each frequency can be changed by setting the respective „Direction“ Parameter (see
parameter 013 resp. 020).
Ds230_03a_oi_e.doc / Jun-15
Page 85 / 100
8.6. Sensor Channel Adaption
When using two sensors with a different number of pulses or in case of a mechanical speed
reduction between both encoders, then the higher frequency must be adjusted to the lower one. For
this calculation the scaling factors (see chapter 7.4.3) are used.
In the example above the frequency 2 is smaller by the factor 0.0994 than frequency 1.
For adjustment, the “Multiplier 1” (parameter 014) should be set to 994 and the “Divisor 1”
(parameter 015) to 10.000.
Ds230_03a_oi_e.doc / Jun-15
Page 86 / 100
By scaling the frequency 1 both internally calculated frequencies are approximately equal and the
calculated ratio is close to "0".
Ds230_03a_oi_e.doc / Jun-15
Page 87 / 100
8.7. Completion of Commissioning
Finally all application-dependent Parameters should be checked for plausibility again. The digital
outputs and relays can be tested for their correct behavior by using the parameter 058 "Output
Action" from the menu "Switching Menu".
The safety-related relay output opens in case of failures or if a programmed switching condition (see
chapter 7.4.5) is reached. Further the contact will be open, if the unit is in the de-energized state.
It is imperative to test the function of the relay and the evaluation in the target device finally!
 The user of the equipment is responsible for ensuring all relevant
parts of the system to a safe state, when the relay contact is open.
After commissioning, the unit state “Operational Mode” must be left by setting the slider 3 of the
DIL switch back to its „ON“ position. For a normal operation always all 3 sliders of the DIL switch
must be set to „ON“.

„Programming Mode“ (DIL switch) only for start-up


Set all DIL switch sliders to „ON“ after start-up
Protect the DIL switch sliders after start-up
(e. g. by covering with an adhesive tape)
Normal operation is only permitted when the yellow LED is permanently off

Ds230_03a_oi_e.doc / Jun-15
Page 88 / 100
9. Error Detection
In order to ensure a maximum of operational safety and reliability, the units are equipped with
several and profound monitoring-functions. The monitoring allows an immediate recognition and
messaging of possible failures and malfunctions.
In case of errors:
 The relay contact switches to its open (safety) condition
(interruption of the safety circuit)
 The analog output (with DS236 and DS246 units) sets to 0 mA
and no more current range (4 … 20 mA) is given.
 All digital outputs are set to LOW (no more inversion between Out X and /Out X)
 No more incremental signals are available at the RS422 output (Tri-State with
pulldown cut off).
 The DC-offset of the SinCos output will be shifted in order o signalize an error to
the target unit.
The following types of error recognition are distinguished:
 Initialization Error
 Runtime Error
Both variants are exactly described in the following two pages…
9.1. Error Representation
Error Representation
Reference
Front LED’s
see chapter 5.14 (LEDs / Status Indication)
Display unit BG230
see BG230 user manual
Operator surface OS6.0
see OS6.0 user manual
Ds230_03a_oi_e.doc / Jun-15
Page 89 / 100
9.2. Initial Error
These monitors / tests are processed automatically when switching the unit on.
Error code
BG230
Error
Operator Software OS6.0
H‘ 0000 0001
ADC Error
H‘ 0000 0002
I2C Error
H‘ 0000 0004
OTH Error
H‘ 0000 0008
SCI Error
H‘ 0000 0010
DIO Error
H‘ 0000 0020
GPI Error
H‘ 0000 0040
CAP Error
H‘ 0000 0080
SPI Error
H‘ 0000 0100
QEP Error
H‘ 0000 0200
SCO Error
H‘ 0000 0400
CPU Error
H‘ 0000 0800
RAM Error
H‘ 0000 1000
WDO Error
Ds230_03a_oi_e.doc / Jun-15
Instruction
Error of the analog output.
See runtime error, error code H‘ 0000 0400
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Error of the control inputs.
See runtime error, error code H‘ 0000 2000
Error of the control inputs.
See runtime error, error code H‘ 0000 2000
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Page 90 / 100
9.3. Runtime Error
These monitors / tests are processed automatically and continuously in the background.
Error code
BG230
Error
Operator Software OS6.0
H‘ 0000 0001
SIN/COS Channel 1 Error
H‘ 0000 0002
H‘ 0000 0004
SIN/COS Channel 2 Error
External Supply Channel 1 Error
H‘ 0000 0008
H‘ 0000 0010
External Supply Channel 2 Error
External Supply BG Error
H‘ 0000 0020
H‘ 0000 0040
H‘ 0000 0080
External Supply BG Status Error
External Supply GV Status Error
External Supply Short Circuit Error
H‘ 0000 0100
Temperature Error
H‘ 0000 0200
Readback Digital Output Error
Ds230_03a_oi_e.doc / Jun-15
Instruction
Error of the input SINCOS IN 1.
Faulty SinCos-encoder, faulty wiring or internal
error of the unit. Check encoder and wiring. If
the error repeats contact manufacturer
See error code H‘ 0000 0001
Error of the encoder supply.
Disconnect encoder supply. Switch off and
switch on the unit.
If error code is off  external error e. g. faulty
wiring or short circuit.
If error code is still active  internal error
(contact manufacturer)
See error code H‘ 0000 0004
Error of the supply of the BG230.
Remove the BG230.
Switch off and switch on the unit.
If error code is off  external error e. g. short
circuit in the BG230.
If error code is still active  internal error
(contact manufacturer)
See error code H‘ 0000 0010
See error code H‘ 0000 0004
See error code H‘ 0000 0004
See error code H‘ 0000 0010
Error of the temperature.
Switch off and cool down the unit.
Switch on the unit.
If error code is off  external error e. g.
illegal temperature range.
If error code is still active  internal error
(contact manufacturer)
Error of the control outputs.
Remove connector at [X2 | CONTROL OUT]
Switch off and switch on the unit.
If error code is off  external error e. g. faulty
wiring or short circuit.
If error code is still active  internal error
(contact manufacturer)
Page 91 / 100
Continuation „Runtime Error“:
Error code
BG230
Error
Operator Software OS6.0
H‘ 0000 0400
Sequence Analog Output Error
H‘ 0000 0800
Readback Relay Output Error
H‘ 0000 1000
H‘ 0000 2000
Readback Analog Output Error
GPI Error
H‘ 0000 4000
H‘ 0000 8000
H‘ 0001 0000
Sequence DAC Output Error
DAC Output Error
Phase Channel 1 Error
H‘ 0002 0000
Phase Channel 2 Error
H‘ 0004 0000
Frequency Error
H‘ 0008 0000
Drift Error 1
H‘ 0010 0000
Drift Error 2
H‘ 0020 0000
ESM Error
H‘ 0040 0000
Wrong Parameter Error Stimulation
H‘ 0080 0000
H‘ 0100 0000
H‘ 0200 0000
H‘ 0400 0000
H‘ 0800 0000
H‘ 1000 0000
Register Error
RTI/QUP Cycle Error
External Clock Error
ADC Error
I2C Error
Initialisation Test Error
Ds230_03a_oi_e.doc / Jun-15
Instruction
Error of the analog output.
Switch off the unit. Remove the wiring and
link X4:2 and X4:3
Switch on the unit.
If error code is off  external error e. g. faulty
wiring or open circuit.
If error code is still active  internal error
(contact manufacturer)
Error of the relay output.
Contact manufacturer.
See error code H‘ 0000 0400
Error of the control inputs.
Faulty wiring, illegal signal states (no
complementary signals) or internal error.
See error code H‘ 0000 0400
See error code H‘ 0000 0400
Error of the phase of Sensor1.
Check parameter 017.
Switch off and switch on the unit.
Error of the phase of Sensor2.
Check parameter 024.
Switch off and switch on the unit.
Error of the divergence.
Check parameter 004 to 021.
Switch off and switch on the unit.
Error of the drift of Sensor1.
Check parameter 016.
Switch off and switch on the unit.
Error of the drift of Sensor2.
Check parameter 023.
Switch off and switch on the unit.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Error of the Error Simulation.
Check parameter 009.
Switch off and switch on the unit.
Internal error. Switch off and switch on the
unit. If the error repeats contact manufacturer.
Page 92 / 100
9.4. Error Clearing
Error states can generally be cleared by switching the power off and on again (after removing the
error source).
9.5. Error Detection Time
Basically it is not possible to specify an exact error detection time because the error detection
depends on many factors.
Reaction time
The error detection time depends (amongst other things) on the following factors:
 Input frequency
 Parameters like:
Sampling Time, Wait Time, Divergence, Power-up Delay, Standstill Time, …
 Reaction time of the output
Ds230_03a_oi_e.doc / Jun-15
Page 93 / 100
10. Parameter List
No.
Parameter
Min. Value
Max. Value
Default
Characters
Decimal Places
Serial Code
000
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
Operational Mode
Sampling Time
Wait Time
F1-F2 Selection
Div. Switch %-f
Div. %-Value
Div. f-Value
Div. Calculation
Div. Filter
Error Simulation
Power-up Delay
Reserved
Reserved
Direction1
Multiplier1
Divisor1
Position Drift1
Phase Err Count1
Set Frequency1
Reserved
Direction2
Multiplier2
Divisor2
Position Drift2
Phase Err Count2
Set Frequency2
Reserved
Preselect OUT1.H
Preselect OUT1.L
Preselect OUT2.H
Preselect OUT2.L
Preselect OUT3.H
Preselect OUT3.L
Preselect OUT4.H
Preselect OUT4.L
Preselect REL1.H
Preselect REL1.L
Reserved
Reserved
0
1
10
0
0
1
0
0
0
0
1
0
0
0
1
1
0
1
-5000000
0
0
1
1
0
1
-5000000
0
-5000000
-5000000
-5000000
-5000000
-5000000
-5000000
-5000000
-5000000
-5000000
-5000000
0
0
9
9999
9999
1
99999
100
9999
1
20
2
1000
10000
10000
1
10000
10000
100000
1000
5000000
10000
1
10000
10000
100000
1000
5000000
10000
5000000
5000000
5000000
5000000
5000000
5000000
5000000
5000000
5000000
5000000
10000
10000
0
1
1000
0
10000
10
3000
0
1
1
100
1000
1000
0
1
1
0
10
0
1000
0
1
1
0
10
0
1000
10000
20000
30000
40000
50000
60000
70000
80000
1000
2000
1000
1000
1
4
4
1
5
3
4
1
2
1
4
5
5
1
5
5
6
4
87
5
1
5
5
6
4
87
5
87
87
87
87
87
87
87
87
87
87
5
5
0
3
3
0
2
0
2
0
0
0
3
0
0
0
0
0
0
0
1
0
0
0
0
0
0
1
0
1
1
1
1
1
1
1
1
1
1
0
0
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
B0
B1
B2
B3
B4
B5
B6
B7
B8
B9
C0
C1
C2
C3
C4
C5
C6
C7
C8
C9
D0
D1
D2
D3
D4
D5
D6
D7
D8
Ds230_03a_oi_e.doc / Jun-15
Page 94 / 100
Continuation „Parameter List“:
No.
Parameter
039
040
041
042
043
044
045
046
047
048
049
050
051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
066
067
068
069
070
071
072
073
074
075
076
077
Switch Mode OUT1
Switch Mode OUT2
Switch Mode OUT3
Switch Mode OUT4
Switch Mode REL1
Pulse Time OUT1
Pulse Time OUT2
Pulse Time OUT3
Pulse Time OUT4
Pulse Time REL1
Hysteresis OUT1
Hysteresis OUT2
Hysteresis OUT3
Hysteresis OUT4
Hysteresis REL1
Startup Mode
Startup Output
Standstill Time
Lock Output
Action Output
Action Polarity
Reserved
Reserved
Input1 Function
Input1 Config
Input2 Function
Input2 Config
Reserved
Reserved
Serial Unit No.
Serial Baud Rate
Serial Format
Serial Page
Serial Init
Reserved
RS Selector
Reserved
Reserved
Reserved
Ds230_03a_oi_e.doc / Jun-15
Min. Value
Max. Value
Default
Characters
Decimal Places
Serial Code
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
11
0
0
0
0
0
0
0
0
0
10
10
10
10
10
9999
9999
9999
9999
9999
1000
1000
1000
1000
1000
10
31
9999
31
31
511
10000
10000
10
3
10
3
10000
10000
99
10
9
11
1
10000
1
10000
10000
10000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1000
1000
0
0
0
0
1000
1000
11
0
0
0
1
1000
0
1000
1000
1000
1
1
1
1
1
4
4
4
4
4
4
4
4
4
4
1
2
4
2
2
3
5
5
1
1
1
1
5
5
2
2
1
2
1
5
1
5
5
5
0
0
0
0
0
3
3
3
3
3
1
1
1
1
1
0
0
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
D9
E0
E1
E2
E3
E4
E5
E6
E7
E8
E9
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
G0
G1
G2
G3
G4
G5
G6
G7
90
91
92
~0
9~
H0
H1
H2
H3
H4
Page 95 / 100
Continuation „Parameter List“:
No.
Parameter
Min. Value
Max. Value
Default
Characters
Decimal Places
Serial Code
078
079
080
081
082
Analog Start
Analog End
Analog Gain
Analog Offset
Reserved
-5000000
-5000000
1
-100
0
5000000
5000000
1000
100
10000
0
100000
100
0
1000
87
87
4
83
5
1
1
0
0
0
H5
H6
H7
H8
H9
Ds230_03a_oi_e.doc / Jun-15
Page 96 / 100
11. Technical Specifications
Power supply:
Encoder supply:
SinCos inputs:
Incremental inputs:
Control-/ incremental
inputs:
SinCos output:
(safety related)
Incremental output:
(safety related)
Analog output:
(safety related)
Control outputs:
(safety related)
Relay output:
(safety related)
Ds230_03a_oi_e.doc / Jun-15
Input voltage:
Protective circuit:
Ripple:
Power consumption:
Protection:
Connections:
Number:
Output voltage:
Output current:
Protection:
Number of inputs:
Signal tracks:
Amplitude:
DC offset:
Frequency:
Connections:
Number of inputs:
Format:
Frequency:
Connections:
Number of inputs:
Application:
Signal level:
Load:
Frequency (control):
Frequency (incremental):
Connections:
Splitter output:
Signal tracks:
Amplitude:
DC offset:
Frequency:
Connection:
Splitter output:
Format:
Frequency:
Connections:
Current output:
Resolution:
Accuracy:
Connection:
Number of outputs:
Output voltage:
Output current:
Switching characteristic:
Protective circuit:
Connection:
Number of relays:
Switching capability:
Switching capacity:
Connection:
18 ... 30 VDC with reverse polarity protection
reverse polarity protection
max. 10 % at 24 VDC
approx. 150 mA (unloaded)
external fuse (2.5 A, medium time lag) necessary
X3, screw terminal, 2-pin, 1.5 mm²
2
approx. 2 VDC less the input voltage
max. 200 mA per encoder
short circuit proof
2
SIN+, SIN-, COS+, COS0.8 ... 1.2 Vpp
2,4 … 2,6 VDC
max. 500 kHz
X6 and X7, SUB-D (male), 9-pin
2
RS422 standard (differential signal A, /A, B, /B)
max. 500 kHz
X8 and X9, screw terminal, 7-pin, 1.5 mm²
2 (each performs complementary)
for HTL encoders, proximity switches or control commands
HTL / PNP (10 ... 30 V)
max. 15 mA
max. 1 kHz
max. 250 kHz
X10, screw terminal, 5-pin, 1.5 mm²
of input SinCos 1
SIN+, SIN-, COS+, COS0.8 ... 1.2 Vpp
2,4 … 2,6 VDC
max. 500 kHz
X5, SUB-D (female), 9-pin
of input SinCos 1, SinCos 2, RS422 1, RS422 2, HTL 1 or HTL 2
proximity switch
RS422 (differential signals A, /A, B, /B)
max. 500 kHz
X4, screw terminal, 7-pin, 1.5 mm²
4 ... 20 mA (load max. 270 Ohm)
14 bit
± 0.1 %
X4, screw terminal, 7-pin, 1.5 mm²
4 (each performs complementary)
HTL (approx. 2 VDC less the input voltage)
max. 30 mA per output
Push-Pull
short-circuit-proof
X2, screw terminal, 8-pin, 1.5 mm²
two relays in series with forced-guided contacts (NO)
5 ... 36 VDC
5 mA ... 5 A
X1, screw terminal, 2-pin, 1.5 mm²
Page 97 / 100
Continuation „Technical Specifications“:
USB interface:
Display:
Switches:
Conformity and standards:
Version:
Connection:
Green LED:
Yellow LED:
DIL switch:
Marking:
MD2006/42EC
RoHs 2011/65/EU:
Classification:
Approved Safety Function:
System structure:
System architecture:
USB 1.0
X12, USB-B (female)
„ON“
„ERROR“
1 x 3-pin
S1
EN ISO 13849-1
EN 61508
EN 62061
EN 61010-1
EN 61000-6-2
EN 61000-6-3
EN 61000-6-4
EN 61326-3-2
EN 60068-2-6
(sine, 7 g, 10 – 200 Hz, 20 cycles)
EN 60068-2-27
(half sine, 30 g, 11 ms, 3 shocks)
EN 60068-2-27
(half sine, 17 g, 6 ms, 4000 shocks)
EN 50581
SIL3/PLe (depends on the used encoder input signals)
Certification No.: 44 207 14018601
dual-channel
Cat. 3 / HFT = 1
DCavg:
SFF:
MTTFD:
PFH:
λSD:
λSU:
λDD:
λDU:
97,07 %
99,2 %
38,1 Jahre
3,76 * 10 -8 h -1
1,93 * 10 -6 h -1
4,64 * 10 -8 h -1
2,94 * 10 -6 h -1
6,14 * 10 -8 h -1
LV 2006/95/EC:
EMC 2004/108/EC:
Vibration resistance:
Shock resistance:
Safety characteristic data:
Safety functions:
Housing:
Ambient temperature:
Programming module
BG230 (optional):
Ds230_03a_oi_e.doc / Jun-15
Material:
Mounting:
Dimensions:
Protection class:
Weight:
Operation:
Storage:
Display:
Operation:
equivalent ... EN61800-5-2 for SS1, SS2, SOS, SLS, SDI,
SSM (depending on the used encoder input signals)
Plastic
to 35 mm top hat rail (according to EN 60715)
50 x 100 x 165 mm (B x H x T)
IP20
approx. 390 g
-20 °C ... +55 °C (without condensation)
-25 °C ... +70 °C (without condensation)
OLED-Display
Touch screen
Page 98 / 100
11.1. Dimensions
(inclusive BG230 at front)
Front:
Rear:
DS230
BG230 (option)
Ds230_03a_oi_e.doc / Jun-15
Page 99 / 100
12. Certificate
Ds230_03a_oi_e.doc / Jun-15
Page 100 / 100